Postcard generator

ABSTRACT

A postcard generator includes an image capture device for capturing and storing an image. The postcard generator also stores a postcard format. The postcard generator receives a supply of print media and prints, using an in-built printer, a postcard having a printed image on one side and the postcard format on the other side. The postcard format includes an address zone and a token indicating that postage has been paid.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This is a Continuation of 09/663,153 filed on Sep. 15, 2000 The present application is a divisional of and claims the benefit of U.S. application Ser. No. 09/113,086 filed on Jul. 10, 1998, the entire contents of which are herein incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates substantially to the concept of a disposable camera having instant printing capabilities and in particular, discloses a method integrating the electronic components of a camera system.

BACKGROUND OF THE INVENTION

[0003] Recently, the concept of a “single use” disposable camera has become an increasingly popular consumer item. Disposable camera systems presently on the market normally include an internal film roll and a simplified gearing mechanism for traversing the film roll across an imaging system including a shutter and lensing system. The user, after utilizing a single film roll returns the camera system to a film development center for processing. The film roll is taken out of the camera system and processed and the prints returned to the user. The camera system is then able to be re-manufactured through the insertion of a new film roll into the camera system, the replacement of any worn or wearable parts and the re-packaging of the camera system in accordance with requirements. In this way, the concept of a single use “disposable” camera is provided to the consumer.

[0004] Recently, a camera system has been proposed by the present applicant which provides for a handheld camera device having an internal print head, image sensor and processing means such that images sense by the image sensing means, are processed by the processing means and adapted to be instantly printed out by the printing means on demand. The proposed camera system further discloses a system of internal “print rolls” carrying print media such as film on to which images are to be printed in addition to ink for supplying to the printing means for the printing process. The print roll is further disclosed to be detachable and replaceable within the camera system.

[0005] Unfortunately, such a system is likely to only be constructed at a substantial cost and it would be desirable to provide for a more inexpensive form of instant camera system which maintains a substantial number of the quality aspects of the aforementioned arrangement

[0006] It would be further advantageous to provide for the effective interconnection of the sub components of a camera system.

SUMMARY OF THE INVENTION

[0007] According to the invention, there is provided a recyclable, one-time use, print on demand, digital camera comprising:

[0008] an image sensor device for sensing an image;

[0009] a processing means for processing said sensed image;

[0010] a pagewidth print head for printing said sensed image;

[0011] an ink supply means for supplying ink to the print head; and

[0012] a supply of print media on to which said image is printed, the supply of print media being pre-marked with tokens designating that postage has been paid so that each image printed out on the print media has one such token associated with it.

[0013] Preferably, the supply of print media is in the form of a roll, the tokens being pre-printed at regularly spaced intervals on one surface of the print media.

[0014] Each token may have an address zone and a blank zone for writing associated with it on said one surface to provide a postcard effect.

[0015] Each image may be printed on an opposed surface of the print media.

[0016] The token may be in the form of a postage stamp which is in a currency of a country in which the camera is bought, with a notice to that effect being carried on an exterior of that camera. Preferably, the camera has a sleeve placed about a casing of the camera. The notice may then be carried on the sleeve of the camera.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Notwithstanding any other forms which may fall within the scope of the present invention, preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0018]FIG. 1 illustrates a front perspective view of the assembled camera of the preferred embodiment;

[0019]FIG. 2 illustrates a rear perspective view, partly exploded, of the preferred embodiment;

[0020]FIG. 3 is a perspective view of the chassis of the preferred embodiment;

[0021]FIG. 4 is a perspective view of the chassis illustrating mounting of electric motors;

[0022]FIG. 5 is an exploded perspective view of the ink supply mechanism of the preferred embodiment;

[0023]FIG. 6 is a rear perspective view of the assembled form of the ink supply mechanism of the preferred embodiment;

[0024]FIG. 7 is a front perspective view of the assembled form of the ink supply mechanism of the preferred embodiment;

[0025]FIG. 8 is an exploded perspective view of the platten unit of the preferred embodiment;

[0026]FIG. 9 is a perspective view of the assembled form of the platten unit;

[0027]FIG. 10 is also a perspective view of the assembled form of the platten unit;

[0028]FIG. 11 is an exploded perspective view of the printhead recapping mechanism of the preferred embodiment;

[0029]FIG. 12 is a close up, exploded perspective view of the recapping mechanism of the preferred embodiment;

[0030]FIG. 13 is an exploded perspective view of the ink supply cartridge of the preferred embodiment;

[0031]FIG. 14 is a close up, perspective view, partly in section, of the internal portions of the ink supply cartridge in an assembled form;

[0032]FIG. 15 is a schematic block diagram of one form of chip layer of the image capture and processing chip of the preferred embodiment;

[0033]FIG. 16 is an exploded perspective view illustrating the assembly process of the preferred embodiment;

[0034]FIG. 17 illustrates a front exploded perspective view of the assembly process of the preferred embodiment;

[0035]FIG. 18 illustrates a perspective view of the assembly process of the preferred embodiment;

[0036]FIG. 19 illustrates a perspective view of the assembly process of the preferred embodiment;

[0037]FIG. 20 is a perspective view illustrating the insertion of the platten unit in the preferred embodiment;

[0038]FIG. 21 illustrates the interconnection of the electrical components of the preferred embodiment;

[0039]FIG. 22 illustrates the process of assembling the preferred embodiment; and

[0040]FIG. 23 is a perspective view further illustrating the assembly process of the preferred embodiment.

DESCRIPTION OF PREFERRED AND OTHER EMBODIMENTS

[0041] Turning initially simultaneously to FIG. 1 and FIG. 2 there are illustrated perspective views of an assembled camera constructed in accordance with the preferred embodiment with FIG. 1 showing a front perspective view and FIG. 2 showing a rear perspective view. The camera 1 includes a paper or plastic film jacket 2 which can include simplified instructions 3 for the operation of the camera system 1. The camera system 1 includes a first “take” button 4 which is depressed to capture an image. The captured image is output via output slot 6. A further copy of the image can be obtained through depressing a second “printer copy” button 7 whilst an LED light 5 is illuminated. The camera system also provides the usual viewfinder 8 in addition to a CCD image capture/lensing system 9.

[0042] The camera system 1 provides for a standard number of output prints after which the camera system 1 ceases to function. A prints left indicator slot 10 is provided to indicate the number of remaining prints. A refund scheme at the point of purchase is assumed to be operational for the return of used camera systems for recycling.

[0043] Turning now to FIG. 3, the assembly of the camera system is based around an internal chassis 12 which can be a plastic injection molded part. A pair of paper pinch rollers 28, 29 utilized for de-curling are snap fitted into corresponding flame holes eg. 26, 27. As shown in FIG. 4, the chassis 12 includes a series of mutually opposed prongs e.g. 13, 14 into which is snapped fitted a series of electric motors 16, 17. The electric motors 16, 17 can be entirely standard with the motor 16 being of a stepper motor type. The motors 16, 17 include cogs 19, 20 for driving a series of gear wheels. A first set of gear wheels is provided for controlling a paper cutter mechanism and a second set is provided for controlling print roll movement.

[0044] Turning next to FIGS. 5 to 7, there is illustrated an ink supply mechanism 40 utilized in the camera system. FIG. 5 illustrates a rear exploded perspective view, FIG. 6 illustrates a rear assembled perspective view and FIG. 7 illustrates a front assembled view. The ink supply mechanism 40 is based around an ink supply cartridge 42 which contains printer ink and a print head mechanism for printing out pictures on demand. The ink supply cartridge 42 includes a side aluminum strip 43 which is provided as a shear strip to assist in cutting images from a paper roll.

[0045] A dial mechanism 44 is provided for indicating the number of “prints left”. The dial mechanism 44 is snap fitted through a corresponding mating portion 46 so as to be freely rotatable.

[0046] As shown in FIG. 6, the mechanism 40 includes a flexible PCB strip 47 which interconnects with the print head and provides for control of the print head. The interconnection between the Flex PCB strip and an image sensor and print head chip can be via Tape Automated Bonding (TAB) strips 51, 58. A molded aspherical lens and aperture shim 50 (FIG. 5) is also provided for imaging an image onto the surface of the image sensor chip normally located within cavity 53 and a light box module or hood 52 is provided for snap fitting over the cavity 53 so as to provide for proper light control. A series of decoupling capacitors e.g. 34 can also be provided. Further a plug 45 (FIG. 7) is provided for re-plugging ink holes after refilling. A series of guide prongs e.g. 55-57 are further provided for guiding the flexible PCB strip 47.

[0047] The ink supply mechanism 40 interacts with a platten unit 60 which guides print media under a printhead located in the ink supply mechanism. FIG. 8 shows an exploded view of the platten unit 60, while FIGS. 9 and 10 show assembled views of the platten unit. The platten unit 60 includes a first pinch roller 61 which is snap fitted to one side of a platten base 62. Attached to a second side of the platten base 62 is a cutting mechanism 63 which traverses the platen unit 60 by means of a rod 64 having a screw thread which is rotated by means of cogged wheel 65 which is also fitted to the platten base 62. The screw threaded rod 64 mounts a block 67 which includes a cutting wheel 68 fastened via a fastener 69. Also mounted to the block 67 is a counter actuator which includes a pawl. The pawl 71 acts to rotate the dial mechanism 44 of FIG. 6 upon the return traversal of the cutting wheel. As shown previously in FIG. 6, the dial mechanism 44 includes a cogged surface which interacts with pawl 71 thereby maintaining a count of the number of photographs by means of numbers embossed on the surface of dial mechanism 44. The cutting mechanism 63 is inserted into the platten base 62 by means of a snap fit via clips e.g. 74.

[0048] The platen unit 60 includes an internal recapping mechanism 80 for recapping the printhead when not in use. The recapping mechanism 80 includes a sponge portion 81 and is operated via a solenoid coil so as to provide for recapping of the print head. In the preferred embodiment, there is provided an inexpensive form of printhead re-capping mechanism provided for incorporation into a handheld camera system so as to provide for printhead re-capping of an inkjet printhead.

[0049]FIG. 11 illustrates an exploded view of the recapping mechanism whilst FIG. 12 illustrates a close up of the end portion thereof. The re-capping mechanism 80 is structured around a solenoid including a 16 turn coil 75 which can comprise insulated wire. The coil 75 is turned around a first stationery solenoid arm 76 which is mounted on a bottom surface of the platen base 62 (FIG. 8) and includes a post portion 77 to magnify effectiveness of operation. The arm 76 can comprise a ferrous material.

[0050] A second moveable arm 78 of the solenoid actuator is also provided. The arm 78 is moveable and is also made of ferrous material. Mounted on the arm is a sponge portion surrounded by an elastomer strip 79. The elastomer strip 79 is of a generally arcuate cross-section and acts as a leaf spring against the surface of the printhead ink supply cartridge 42 (FIG. 5) so as to provide for a seal against the surface of the printhead ink supply cartridge 42. In the quiescent position an elastomer spring unit 87, 88 acts to resiliently deform the elastomer seal 79 against the surface of the ink supply unit 42.

[0051] When it is desired to operate the printhead unit, upon the insertion of paper, the solenoid coil 75 is activated so as to cause the arm 78 to move down to be adjacent to the end plate 76. The arm 78 is held against end plate 76 while the printhead is printing by means of a small “keeper current” in coil 75. Simulation results indicate that the keeper current can be significantly less than the actuation current. Subsequently, after photo printing, the paper is guillotined by the cutting mechanism 63 of FIG. 8 acting against aluminum strip 43, and rewound so as to clear the area of the re-capping mechanism 80. Subsequently, the current is turned off and springs 87, 88 return the arm 78 so that the elastomer seal is again resting against the printhead ink supply cartridge.

[0052] It can be seen that the preferred embodiment provides for a simple and inexpensive means of re-capping a printhead through the utilization of a solenoid type device having a long rectangular form.

[0053] Further, the preferred embodiment utilizes minimal power in that currents are only required whilst the device is operational and additionally, only a low keeper current is required whilst the printhead is printing.

[0054] Turning next to FIGS. 13 and 14, FIG. 13 illustrates an exploded perspective of the ink supply cartridge 42 whilst FIG. 14 illustrates a close up sectional view of a bottom of the ink supply cartridge with the printhead unit in place. The ink supply cartridge 42 is based around a pagewidth printhead 102 which comprises a long slither of silicon having a series of holes etched on the back surface for the supply of ink to a front surface of the silicon wafer for subsequent ejection via a micro electromechanical system. The form of ejection can be many different forms such as those set out in the tables below.

[0055] Of course, many other inkjet technologies, as referred to the attached tables below, can also be utilized when constructing a printhead unit 102. The fundamental requirement of the ink supply cartridge 42 is the supply of ink to a series of color channels etched through the back surface of the printhead 102. In the description of the preferred embodiment, it is assumed that a three color printing process is to be utilized so as to provide full color picture output. Hence, the print supply unit includes three ink supply reservoirs being a cyan reservoir 104, a magenta reservoir 105 and a yellow reservoir 106. Each of these reservoirs is required to store ink and includes a corresponding sponge type material 107-109 which assists in stabilizing ink within the corresponding ink channel and inhibiting the ink from sloshing back and forth when the printhead is utilized in a handheld camera system. The reservoirs 104, 105, 106 are formed through the mating of first exterior plastic piece 110 and a second base piece 111.

[0056] At a first end 118 of the base piece 111 a series of air inlet 113-115 are provided. Each air inlet leads to a corresponding winding channel which is hydrophobically treated so as to act as an ink repellent and therefore repel any ink that may flow along the air inlet channel. The air inlet channel further takes a convoluted path assisting in resisting any ink flow out of the chambers 104-106. An adhesive tape portion 117 is provided for sealing the channels within end portion 118.

[0057] At the top end, there is included a series of refill holes (not shown) for refilling corresponding ink supply chambers 104, 105, 106. A plug 121 is provided for sealing the refill holes.

[0058] Turning now to FIG. 14, there is illustrated a close up perspective view, partly in section through the ink supply cartridge 42 of FIG. 13 when formed as a unit. The ink supply cartridge includes the three color ink reservoirs 104, 105, 106 which supply ink to different portions of the back surface of printhead 102 which includes a series of apertures 128 defined therein for carriage of the ink to the front surface.

[0059] The ink supply cartridge 42 includes two guide walls 124, 125 which separate the various ink chambers and are tapered into an end portion abutting the surface of the printhead 102. The guide walls 124, 125 are further mechanically supported by block portions e.g. 126 which are placed at regular intervals along the length of the ink supply unit. The block portions 126 have space at portions close to the back of printhead 102 for the flow of ink around the back surface thereof.

[0060] The ink supply unit is preferably formed from a multi-part plastic injection mold and the mold pieces e.g. 110, 111 (FIG. 13) snap together around the sponge pieces 107, 109. Subsequently, a syringe type device can be inserted in the ink refill holes and the ink reservoirs filled with ink with the air flowing out of the air outlets 113-115. Subsequently, the adhesive tape portion 117 and plug 121 are attached and the printhead tested for operation capabilities. Subsequently, the ink supply cartridge 42 can be readily removed for refilling by means of removing the ink supply cartridge, performing a washing cycle, and then utilizing the holes for the insertion of a refill syringe filled with ink for refilling the ink chamber before returning the ink supply cartridge 42 to a camera.

[0061] Turning now to FIG. 15, there is shown an example layout of the Image Capture and Processing Chip (ICP) 48.

[0062] The Image Capture and Processing Chip 48 provides most of the electronic functionality of the camera with the exception of the print head chip. The chip 48 is a highly integrated system. It combines CMOS image sensing, analog to digital conversion, digital image processing, DRAM storage, ROM, and miscellaneous control functions in a single chip.

[0063] The chip is estimated to be around 32 mm² using a leading edge 0.18 micron CMOS/DRAM/APS process. The chip size and cost can scale somewhat with Moore's law, but is dominated by a CMOS active pixel sensor array 201, so scaling is limited as the sensor pixels approach the diffraction limit.

[0064] The ICP 48 includes CMOS logic, a CMOS image sensor, DRAM, and analog circuitry. A very small amount of flash memory or other non-volatile memory is also preferably included for protection against reverse engineering.

[0065] Alternatively, the ICP can readily be divided into two chips: one for the CMOS imaging array, and the other for the remaining circuitry. The cost of this two chip solution should not be significantly different than the single chip ICP, as the extra cost of packaging and bond-pad area is somewhat cancelled by the reduced total wafer area requiring the color filter fabrication steps.

[0066] The ICP preferably contains the following functions: Function 1.5 megapixel image sensor Analog Signal Processors Image sensor column decoders Image sensor row decoders Analogue to Digital Conversion (ADC) Column ADC's Auto exposure 12 Mbits of DRAM DRAM Address Generator Color interpolator Convolver Color ALU Halftone matrix ROM Digital halftoning Print head interface 8 bit CPU core Program ROM Flash memory Scratchpad SRAM Parallel interface (8 bit) Motor drive transistors (5) Clock PLL JTAG test interface Test circuits Busses Bond pads

[0067] The CPU, DRAM, Image sensor, ROM, Flash memory, Parallel interface, JTAG interface and ADC can be vendor supplied cores. The ICP is intended to run on 1.5V to minimize power consumption and allow convenient operation from two AA type battery cells.

[0068]FIG. 15 illustrates a layout of the ICP 48. The ICP 48 is dominated by the imaging array 201, which consumes around 80% of the chip area. The imaging array is a CMOS 4 transistor active pixel design with a resolution of 1,500×1,000. The array can be divided into the conventional configuration, with two green pixels, one red pixel, and one blue pixel in each pixel group. There are 750×500 pixel groups in the imaging array.

[0069] The latest advances in the field of image sensing and CMOS image sensing in particular can be found in the October, 1997 issue of IEEE Transactions on Electron Devices and, in particular, pages 1689 to 1968. Further, a specific implementation similar to that disclosed in the present application is disclosed in

[0070] Wong et al., “CMOS Active Pixel Image Sensors Fabricated Using a 1.8V, 0.25 μm CMOS Technology”, IEDM 1996, page 915

[0071] The imaging array uses a 4 transistor active pixel design of a standard configuration. To minimize chip area and therefore cost, the image sensor pixels should be as small as feasible with the technology available. With a four transistor cell, the typical pixel size scales as 20 times the lithographic feature size. This allows a minimum pixel area of around 3.6 μm×3.6 μm. However, the photosite must be substantially above the diffraction limit of the lens. It is also advantageous to have a square photosite, to maximize the margin over the diffraction limit in both horizontal and vertical directions. In this case, the photosite can be specified as 2.5 μm×2.5 μm. The photosite can be a photogate, pinned photodiode, charge modulation device, or other sensor.

[0072] The four transistors are packed as an ‘L’ shape, rather than a rectangular region, to allow both the pixel and the photosite to be square. This reduces the transistor packing density slightly, increasing pixel size. However, the advantage in avoiding the diffraction limit is greater than the small decrease in packing density.

[0073] The transistors also have a gate length which is longer than the minimum for the process technology. These have been increased from a drawn length of 0.18 micron to a drawn length of 0.36 micron. This is to improve the transistor matching by making the variations in gate length represent a smaller proportion of the total gate length.

[0074] The extra gate length, and the ‘L’ shaped packing, mean that the transistors use more area than the minimum for the technology. Normally, around 8 μm² would be required for rectangular packing. Preferably, 9.75 μm² has been allowed for the transistors.

[0075] The total area for each pixel is 16 μm², resulting from a pixel size of 4 μm×4 μm. With a resolution of 1,500×1,000, the area of the imaging array 101 is 6,000 μm×4,000 μm or 24 mm².

[0076] The presence of a color image sensor on the chip affects the process required in two major ways:

[0077] The CMOS fabrication process should be optimised to minimize dark current

[0078] Color filters are required. These can be fabricated using dyed photosensitive polyimides, resulting in an added process complexity of three spin coatings, three photolithographic steps, three development steps, and three hardbakes.

[0079] There are 15,000 analog signal processors (ASPs) 205, one for each of the columns of the sensor. The ASPs amplify the signal, provide a dark current reference, sample and hold the signal, and suppress the fixed pattern noise (FPN).

[0080] There are 375 analog to digital converters 206, one for each four columns of the sensor array. These may be delta-sigma or successive approximation type ADC's. A row of low column ADC's are used to reduce the conversion speed required, and the amount of analog signal degradation incurred before the signal is converted to digital. This also eliminates the hot spot (affecting local dark current) and the substrate coupled noise that would occur if a single high speed ADC was used. Each ADC also has two four bit DAC's which trim the offset and scale of the ADC to further reduce FPN variations between columns. These DAC's are controlled by data stored in flash memory during chip testing.

[0081] The column select logic 204 is a 1:1500 decoder which enables the appropriate digital output of the ADCs onto the output bus. As each ADC is shared by four columns, the least significant two bits of the row select control 4 input analog multiplexors.

[0082] A row decoder 207 is a 1:1000 decoder which enables the appropriate row of the active pixel sensor array. This selects which of the 1000 rows of the imaging array is connected to analog signal processors. As the rows are always accessed in sequence, the row select logic can be implemented as a shift register.

[0083] An auto exposure system 208 adjusts the reference voltage of the ADC 205 in response to the maximum intensity sensed during the previous frame period. Data from the green pixels is passed through a digital peak detector. The peak value of the image frame period before capture (the reference frame) is provided to a digital to analogue converter (DAC), which generates the global reference voltage for the column ADCs. The peak detector is reset at the beginning of the reference frame. The minimum and maximum values of the three RGB color components are also collected for color correction.

[0084] The second largest section of the chip is consumed by a DRAM 210 used to hold the image. To store the 1,500×1,000 image from the sensor without compression, 1.5 Mbytes of DRAM 210 are required. This equals 12 Mbits, or slightly less than 5% of a 256 Mbit DRAM. The DRAM technology assumed is of the 256 Mbit generation implemented using 0.18 μm CMOS.

[0085] Using a standard 8F cell, the area taken by the memory array is 3.11 mm². When row decoders, column sensors, redundancy, and other factors are taken into account, the DRAM requires around 4 mm².

[0086] This DRAM 210 can be mostly eliminated if analog storage of the image signal can be accurately maintained in the CMOS imaging array for the two seconds required to print the photo. However, digital storage of the image is preferable as it is maintained without degradation, is insensitive to noise, and allows copies of the photo to be printed considerably later.

[0087] A DRAM address generator 211 provides the write and read addresses to the DRAM 210. Under normal operation, the write address is determined by the order of the data read from the CMOS image sensor 201. This will typically be a simple raster format. However, the data can be read from the sensor 201 in any order, if matching write addresses to the DRAM are generated. The read order from the DRAM 210 will normally simply match the requirements of a color interpolator and the print head. As the cyan, magenta, and yellow rows of the print head are necessarily offset by a few pixels to allow space for nozzle actuators, the colors are not read from the DRAM simultaneously. However, there is plenty of time to read all of the data from the DRAM many times during the printing process. This capability is used to eliminate the need for FIFOs in the print head interface, thereby saving chip area. All three RGB image components can be read from the DRAM each time color data is required. This allows a color space converter to provide a more sophisticated conversion than a simple linear RGB to CMY conversion.

[0088] Also, to allow two dimensional filtering of the image data without requiring line buffers, data is re-read from the DRAM array.

[0089] The address generator may also implement image effects in certain models of camera. For example, passport photos are generated by a manipulation of the read addresses to the DRAM. Also, image framing effects (where the central image is reduced), image warps, and kaleidoscopic effects can all be generated by manipulating the read addresses of the DRAM.

[0090] While the address generator 211 may be implemented with substantial complexity if effects are built into the standard chip, the chip area required for the address generator is small, as it consists only of address counters and a moderate amount of random logic.

[0091] A color interpolator 214 converts the interleaved pattern of red, 2×green, and blue pixels into RGB pixels. It consists of three 8 bit adders and associated registers. The divisions are by either 2 (for green) or 4 (for red and blue) so they can be implemented as fixed shifts in the output connections of the adders.

[0092] A convolver 215 is provided as a sharpening filter which applies a small convolution kernel (5×5) to the red, green, and blue planes of the image. The convolution kernel for the green plane is different from that of the red and blue planes, as green has twice as many samples. The sharpening filter has five functions:

[0093] to improve the color interpolation from the linear interpolation provided by the color interpolator, to a close approximation of a sinc interpolation;

[0094] to compensate for the image ‘softening’ which occurs during digitisation;

[0095] to adjust the image sharpness to match average consumer preferences, which are typically for the image to be slightly sharper than reality. As the single use camera is intended as a consumer product, and not a professional photographic products, the processing can match the most popular settings, rather than the most accurate;

[0096] to suppress the sharpening of high frequency (individual pixel) noise. The function is similar to the ‘unsharp mask’ process; and

[0097] to antialias Image Warping.

[0098] These functions are all combined into a single convolution matrix. As the pixel rate is low (less than 1 Mpixel per second) the total number of multiplies required for the three color channels is 56 million multiplies per second. This can be provided by a single multiplier. Fifty bytes of coefficient ROM are also required.

[0099] A color ALU 113 combines the functions of color compensation and color space conversion into the one matrix multiplication, which is applied to every pixel of the frame. As with sharpening, the color correction should match the most popular settings, rather than the most accurate.

[0100] A color compensation circuit of the color ALU provides compensation for the lighting of the photo. The vast majority of photographs are substantially improved by a simple color compensation, which independently normalizes the contrast and brightness of the three color components.

[0101] A color look-up table (CLUT) 212 is provided for each color component. These are three separate 256×8 SRAMs, requiring a total of 6,144 bits. The CLUTs are used as part of the color correction process. They are also used for color special effects, such as stochastically selected “wild color” effects.

[0102] A color space conversion system of the color ALU converts from the RGB color space of the image sensor to the CMY color space of the printer. The simplest conversion is a 1's complement of the RGB data. However, this simple conversion assumes perfect linearity of both color spaces, and perfect dye spectra for both the color filters of the image sensor, and the ink dyes. At the other extreme is a tri-linear interpolation of a sampled three dimensional arbitrary transform table. This can effectively match any non-linearity or differences in either color space. Such a system is usually necessary to obtain good color space conversion when the print engine is a color electrophotographic

[0103] However, since the non-linearity of a halftoned ink jet output is very small, a simpler system can be used. A simple matrix multiply can provide excellent results. This requires nine multiplies and six additions per contone pixel. However, since the contone pixel rate is low (less than 1 Mpixel/sec) these operations can share a single multiplier and adder. The multiplier and adder are used in a color ALU which is shared with the color compensation function.

[0104] Digital halftoning can be performed as a dispersed dot ordered dither using a stochastic optimized dither cell. A halftone matrix ROM 216 is provided for storing dither cell coefficients. A dither cell size of 32×32 is adequate to ensure that the cell repeat cycle is not visible. The three colors—cyan, magenta, and yellow—are all dithered using the same cell, to ensure maximum co-positioning of the ink dots. This minimizes ‘muddying’ of the mid-tones which results from bleed of dyes from one dot to adjacent dots while still wet. The total ROM size required is 1 KByte, as the one ROM is shared by the halftoning units for each of the three colors.

[0105] The digital halftoning used is dispersed dot ordered dither with stochastic optimized dither matrix. While dithering does not produce an image quite as ‘sharp’ as error diffusion, it does produce a more accurate image with fewer artifacts. The image sharpening produced by error diffusion is artificial, and less controllable and accurate than ‘unsharp mask’ filtering performed in the contone domain. The high print resolution (1,600 dpi×1,600 dpi) results in excellent quality when using a well formed stochastic dither matrix.

[0106] Digital halftoning is performed by a digital halftoning unit 217 using a simple comparison between the contone information from the DRAM 210 and the contents of the dither matrix 216. During the halftone process, the resolution of the image is changed from the 250 dpi of the captured contone image to the 1,600 dpi of the printed image. Each contone pixel is converted to an average of 40.96 halftone dots.

[0107] The ICP incorporates a 16 bit microcontroller CPU core 219 to run the miscellaneous camera functions, such as reading the buttons, controlling the motor and solenoids, setting up the hardware, and authenticating the refill station. The processing power required by the CPU is very modest, and a wide variety of processor cores can be used. As the entire CPU program is run from a small ROM 220 program compatibility between camera versions is not important, as no external programs are run. A 2 Mbit (256 Kbyte) program and data ROM 220 is included on chip. Most of this ROM space is allocated to data for outline graphics and fonts for specialty cameras. The program requirements are minor. The single most complex task is the encrypted authentication of the refill station. The ROM requires a single transistor per bit.

[0108] A Flash memory 221 may be used to store a 128 bit authentication code. This provides higher security than storage of the authentication code in ROM, as reverse engineering can be made essentially impossible. The Flash memory is completely covered by third level metal, making the data impossible to extract using scanning probe microscopes or electron beams. The authentication code is stored in the chip when manufactured. At least two other Flash bits are required for the authentication process: a bit which locks out reprogramming of the authentication code, and a bit which indicates that the camera has been refilled by an authenticated refill station. The flash memory can also be used to store FPN correction data for the imaging array. Additionally, a phase locked loop rescaling parameter is stored for scaling the clocking cycle to an appropriate correct time. The clock frequency does not require crystal accuracy since no date functions are provided. To eliminate the cost of a crystal, an on chip oscillator with a phase locked loop 224 is used. As the frequency of an on-chip oscillator is highly variable from chip to chip, the frequency ratio of the oscillator to the PLL is digitally trimmed during initial testing. The value is stored in Flash memory 221. This allows the clock PLL to control the ink-jet heater pulse width with sufficient accuracy.

[0109] A scratchpad SRAM is a small static RAM 222 with a 6T cell. The scratchpad provided temporary memory for the 16 bit CPU. 1024 bytes is adequate.

[0110] A print head interface 223 formats the data correctly for the print head. The print head interface also provides all of the timing signals required by the print head. These timing signals may vary depending upon temperature, the number of dots printed simultaneously, the print medium in the print roll, and the dye density of the ink in the print roll.

[0111] The following is a table of external connections to the print head interface: Connection Function Pins DataBits[0-7] Independent serial data to the eight segments of the printhead 8 BitClock Main data clock for the print head 1 ColorEnable[0-2] Independent enable signals for the CMY actuators, allowing different 3 pulse times for each color. BankEnable[0-1] Allows either simultaneous or interleaved actuation of two banks of 2 nozzles. This allows two different print speed/power consumption tradeoffs NozzleSelect[0-4] Selects one of 32 banks of nozzles for simultaneous actuation 5 ParallelXferClock Loads the parallel transfer register with the data from the shift registers 1 Total 20

[0112] The printhead utilized is composed of eight identical segments, each 1.25 cm long. There is no connection between the segments on the print head chip. Any connections required are made in the external TAB bonding film, which is double sided. The division into eight identical segments is to simplify lithography using wafer steppers. The segment width of 1.25 cm fits easily into a stepper field. As the printhead chip is long and narrow (10 cm×0.3 mm), the stepper field contains a single segment of 32 print head chips. The stepper field is therefore 1.25 cm×1.6 cm. An average of four complete print heads are patterned in each wafer step.

[0113] A single BitClock output line connects to all 8 segments on the printhead. The 8 DataBits lines lead one to each segment, and are clocked into the 8 segments on the print head simultaneously (on a BitClock pulse). For example, dot 0 is transferred to segment₀, dot 750 is transferred to segment₁, dot 1500 to segment₂ etc simultaneously.

[0114] The ParallelXferClock is connected to each of the 8 segments on the printhead, so that on a single pulse, all segments transfer their bits at the same time.

[0115] The NozzleSelect, BankEnable and ColorEnable lines are connected to each of the 8 segments, allowing the print head interface to independently control the duration of the cyan, magenta, and yellow nozzle energizing pulses. Registers in the Print Head Interface allow the accurate specification of the pulse duration between 0 and 6 ms, with a typical duration of 2 ms to 3 ms.

[0116] A parallel interface 125 connects the ICP to individual static electrical signals. The CPU is able to control each of these connections as memory mapped I/O via a low speed bus.

[0117] The following is a table of connections to the parallel interface: Connection Direction Pins Paper transport stepper motor Output 4 Capping solenoid Output 1 Copy LED Output 1 Photo button Input 1 Copy button Input 1 Total 8

[0118] Seven high current drive transistors e.g. 227 are required. Four are for the four phases of the main stepper motor two are for the guillotine motor, and the remaining transistor is to drive the capping solenoid.

[0119] These transistors are allocated 20,000 square microns (600,000 F) each. As the transistors are driving highly inductive loads, they must either be turned off slowly, or be provided with a high level of back EMF protection. If adequate back EMF protection cannot be provided using the chip process chosen, then external discrete transistors should be used. The transistors are never driven at the same time as the image sensor is used. This is to avoid voltage fluctuations and hot spots affecting the image quality. Further, the transistors are located as far away from the sensor as possible.

[0120] A standard JTAG (Joint Test Action Group) interface 228 is included in the ICP for testing purposes and for interrogation by the refill station. Due to the complexity of the chip, a variety of testing techniques are required, including BIST (Built In Self Test) and functional block isolation. An overhead of 10% in chip area is assumed for chip testing circuitry for the random logic portions. The overhead for the large arrays the image sensor and the DRAM is smaller.

[0121] The JTAG interface is also used for authentication of the refill station. This is included to ensure that the cameras are only refilled with quality paper and ink at a properly constructed refill station, thus preventing inferior quality refills from occurring. The camera must authenticate the refill station, rather than vice versa. The secure protocol is communicated to the refill station during the automated test procedure. Contact is made to four gold plated spots on the ICP/print head TAB by the refill station as the new ink is injected into the print head.

[0122]FIG. 16 illustrates a rear view of the next step in the construction process whilst FIG. 17 illustrates a front view.

[0123] Turning now to FIG. 16, the assembly of the camera system proceeds via first assembling the ink supply mechanism 40. The flex PCB is interconnected with batteries 84, only one of which is shown, which are inserted in the middle portion of a print roll 85 which is wrapped around a plastic former 86. An end cap 89 is provided at the other end of the print roll 85 so as to fasten the print roll and batteries firmly to the ink supply mechanism.

[0124] The solenoid coil is interconnected (not shown) to interconnects 97, 98 (FIG. 8) which include leaf spring ends for interconnection with electrical contacts on the Flex PCB so as to provide for electrical control of the solenoid.

[0125] Turning now to FIGS. 17-19 the next step in the construction process is the insertion of the relevant gear trains into the side of the camera chassis. FIG. 17 illustrates a front view, FIG. 18 illustrates a rear view and FIG. 19 also illustrates a rear view. The first gear train comprising gear wheels 22, 23 is utilized for driving the guillotine blade with the gear wheel 23 engaging the gear wheel 65 of FIG. 8. The second gear train comprising gear wheels 24, 25 and 26 engage one end of the print roller 61 of FIG. 8. As best indicated in FIG. 18, the gear wheels mate with corresponding pins on the surface of the chassis with the gear wheel 26 being snap fitted into corresponding mating hole 27.

[0126] Next, as illustrated in FIG. 20, the assembled platten unit 60 is then inserted between the print roll 85 and aluminum cutting blade 43.

[0127] Turning now to FIG. 21, by way of illumination, there is illustrated the electrically interactive components of the camera system. As noted previously, the components are based around a Flex PCB board and include a TAB film 58 which interconnects the printhead 102 with the image sensor and processing chip 48. Power is supplied by two AA type batteries 83, 84 and a paper drive stepper motor 16 is provided in addition to a rotary guillotine motor 17.

[0128] An optical element 31 is provided for snapping into a top portion of the chassis 12. The optical element 31 includes portions defining an optical view finder 32, 33 which are slotted into mating portions 35, 36 in view finder channel 37. Also provided in the optical element 31 is a lensing system 38 for magnification of the prints left number in addition to an optical pipe element 39 for piping light from the LED 5 for external display.

[0129] Turning next to FIG. 22, the assembled unit 90 is then inserted into a front outer case 91 which includes button 4 for activation of printouts.

[0130] Turning now to FIG. 23, next, the unit 90 is provided with a snap-on back cover 93 which includes a slot 6 and copy print button 7. A wrapper label containing instructions and advertising (not shown) is then wrapped around the outer surface of the camera system and pinch clamped to the cover by means of clamp strip 96 which can comprise a flexible plastic or rubber strip.

[0131] Subsequently, the preferred embodiment is ready for use as a one time use camera system that provides for instant output images on demand. It will be evident that the preferred embodiment further provides for a refillable camera system. A used camera can be collected and its outer plastic cases removed and recycled. A new paper roll and batteries can be added and the ink cartridge refilled. A series of automatic test routines can then be carried out to ensure that the printer is properly operational. Further, in order to ensure only authorized refills are conducted so as to enhance quality, routines in the on-chip program ROM can be executed such that the camera authenticates the refilling station using a secure protocol. Upon authentication, the camera can reset an internal paper count and an external case can be fitted on the camera system with a new outer label. Subsequent packing and shipping can then take place.

[0132] It will be further readily evident to those skilled in the art that the program ROM can be modified so as to allow for a variety of digital processing routines. In addition to the digitally enhanced photographs optimized for mainstream consumer preferences, various other models can readily be provided through mere re-programming of the program ROM. For example, a sepia classic old fashion style output can be provided through a remapping of the color mapping function. A further alternative is to provide for black and white outputs again through a suitable color remapping algorithm. Minimum color can also be provided to add a touch of color to black and white prints to produce the effect that was traditionally used to colorize black and white photos. Further, passport photo output can be provided through suitable address remappings within the address generators. Further, edge filters can be utilized as is known in the field of image processing to produce sketched art styles. Further, classic wedding borders and designs can be placed around an output image in addition to the provision of relevant clip arts. For example, a wedding style camera might be provided. Further, a panoramic mode can be provided so as to output the well known panoramic format of images. Further, a postcard style output can be provided through the printing of postcards including postage on the back of a print roll surface. Further, cliparts can be provided for special events such as Halloween, Christmas etc. Further, kaleidoscopic effects can be provided through address remappings and wild color effects can be provided through remapping of the color lookup table. Many other forms of special event cameras can be provided for example, cameras dedicated to the Olympics, movie tie-ins, advertising and other special events.

[0133] The operational mode of the camera can be programmed so that upon the depressing of the take photo a first image is sampled by the sensor array to determine irrelevant parameters. Next a second image is again captured which is utilized for the output. The captured image is then manipulated in accordance with any special requirements before being initially output on the paper roll. The LED light is then activated for a predetermined time during which the DRAM is refreshed so as to retain the image. If the print copy button is depressed during this predetermined time interval, a further copy of the photo is output. After the predetermined time interval where no use of the camera has occurred, the onboard CPU shuts down all power to the camera system until such time as the take button is again activated. In this way, substantial power savings can be realized.

[0134] Ink Jet Technologies

[0135] The embodiments of the invention use an ink jet printer type device. Of course many different devices could be used. However presently popular ink jet printing technologies are unlikely to be suitable.

[0136] The most significant problem with thermal inkjet is power consumption. This is approximately 100 times that required for high speed, and stems from the energy-inefficient means of drop ejection. This involves the rapid boiling of water to produce a vapor bubble which expels the ink. Water has a very high heat capacity, and must be superheated in thermal inkjet applications. This leads to an efficiency of around 0.02%, from electricity input to drop momentum (and increased surface area) out.

[0137] The most significant problem with piezoelectric inkjet is size and cost. Piezoelectric crystals have a very small deflection at reasonable drive voltages, and therefore require a large area for each nozzle. Also, each piezoelectric actuator must be connected to its drive circuit on a separate substrate. This is not a significant problem at the current limit of around 300 nozzles per print head, but is a major impediment to the fabrication of pagewidth print heads with 19,200 nozzles.

[0138] Ideally, the inkjet technologies used meet the stringent requirements of in-camera digital color printing and other high quality, high speed, low cost printing applications. To meet the requirements of digital photography, new inkjet technologies have been created. The target features include:

[0139] low power (less than 10 Watts)

[0140] high resolution capability (1,600 dpi or more)

[0141] photographic quality output

[0142] low manufacturing cost

[0143] small size (pagewidth times minimum cross section)

[0144] high speed (<2 seconds per page).

[0145] All of these features can be met or exceeded by the inkjet systems described below with differing levels of difficulty forty-five different inkjet technologies have been developed by the Assignee to give a wide range of choices for high volume manufacture. These technologies form part of separate applications assigned to the present Assignee as set out in the table below.

[0146] The inkjet designs shown here are suitable for a wide range of digital printing systems, from battery powered one-time use digital cameras, through to desktop and network printers, and through to commercial printing systems

[0147] For ease of manufacture using standard process equipment, the printhead is designed to be a monolithic 0.5 micron CMOS chip with MEMS post processing. For color photographic applications, the print head is 100 mm long, with a width which depends upon the inkjet type. The smallest print head designed is IJ38, which is 0.35 mm wide, giving a chip area of 35 square mm. The print heads each contain 19,200 nozzles plus data and control circuitry.

[0148] Ink is supplied to the back of the print head by injection molded plastic ink channels. The molding requires 50 micron features, which can be created using a lithographically micromachined insert in a standard injection molding tool. Ink flows through holes etched through the wafer to the nozzle chambers fabricated on the front surface of the wafer. The print head is connected to the camera circuitry by tape automated bonding.

CROSS-REFERENCED APPLICATIONS

[0149] The following table is a guide to cross-referenced patent applications filed concurrently herewith and discussed hereinafter with the reference being utilized in subsequent tables when referring to a particular case: Docket No. Reference Title IJ01US IJ01 Radiant Plunger Ink Jet Printer IJ02US IJ02 Electrostatic Ink Jet Printer IJ03US IJ03 Planar Thermoelastic Bend Actuator Ink Jet IJ04US IJ04 Stacked Electrostatic Ink Jet Printer IJ05US IJ05 Reverse Spring Lever Ink Jet Printer IJ06US IJ06 Paddle Type Ink Jet Printer IJ07US IJ07 Permanent Magnet Electromagnetic Ink Jet Printer IJ08US IJ08 Planar Swing Grill Electromagnetic Ink Jet Printer IJ09US IJ09 Pump Action Refill Ink Jet Printer IJ10US IJ10 Pulsed Magnetic Field Ink Jet Printer IJ11US IJ11 Two Plate Reverse Firing Electromagnetic Ink Jet Printer IJ12US IJ12 Linear Stepper Actuator Ink Jet Printer IJ13US IJ13 Gear Driven Shutter Ink Jet Printer IJ14US IJ14 Tapered Magnetic Pole Electromagnetic Ink Jet Printer IJ15US IJ15 Linear Spring Electromagnetic Grill Ink Jet Printer IJ16US IJ16 Lorenz Diaphragm Electromagnetic Ink Jet Printer IJ17US IJ17 PTFE Surface Shooting Shuttered Oscillating Pressure Ink Jet Printer IJ18US IJ18 Buckle Grip Oscillating Pressure Ink Jet Printer IJ19US IJ19 Shutter Based Ink Jet Printer IJ20US IJ20 Curling Calyx Thermoelastic Ink Jet Printer IJ21US IJ21 Thermal Actuated Ink Jet Printer IJ22US IJ22 Iris Motion Ink Jet Printer IJ23US IJ23 Direct Firing Thermal Bend Actuator Ink Jet Printer IJ24US IJ24 Conductive PTFE Ben Activator Vented Ink Jet Printer IJ25US IJ25 Magnetostrictive Ink Jet Printer IJ26US IJ26 Shape Memory Alloy Ink Jet Printer IJ27US IJ27 Buckle Plate Ink Jet Printer IJ28US IJ28 Thermal Elastic Rotary Impeller Ink Jet Printer IJ29US IJ29 Thermoelastic Bend Actuator Ink Jet Printer IJ30US IJ30 Thermoelastic Bend Actuator Using PTFE and Corrugated Copper Ink Jet Printer IJ31US IJ31 Bend Actuator Direct Ink Supply Ink Jet Printer IJ32US IJ32 A High Young's Modulus Thermoelastic Ink Jet Printer IJ33US IJ33 Thermally actuated slotted chamber wall ink jet printer IJ34US IJ34 Ink Jet Printer having a thermal actuator comprising an external coiled spring IJ35US IJ35 Trough Container Ink Jet Printer IJ36US IJ36 Dual Chamber Single Vertical Actuator Ink Jet IJ37US IJ37 Dual Nozzle Single Horizontal Fulcrum Actuator Ink Jet IJ38US IJ38 Dual Nozzle Single Horizontal Actuator Ink Jet IJ39US IJ39 A single bend actuator cupped paddle ink jet printing device IJ40US IJ40 A thermally actuated ink jet printer having a series of thermal actuator units IJ41US IJ41 A thermally actuated ink jet printer including a tapered heater element IJ42US IJ42 Radial Back-Curling Thermoelastic Ink Jet IJ43US IJ43 Inverted Radial Back-Curling Thermoelastic Ink Jet IJ44US IJ44 Surface bend actuator vented ink supply ink jet printer IJ45US IJ45 Coil Acutuated Magnetic Plate Ink Jet Printer

[0150] Tables of Drop-on-Demand Inkjets

[0151] Eleven important characteristics of the fundamental operation of individual inkjet nozzles have been identified. These characteristics are largely orthogonal, and so can be elucidated as an eleven dimensional matrix. Most of the eleven axes of this matrix include entries developed by the present assignee.

[0152] The following tables form the axes of an eleven dimensional table of inkjet types.

[0153] Actuator mechanism (18 types)

[0154] Basic operation mode (7 types)

[0155] Auxiliary mechanism (8 types)

[0156] Actuator amplification or modification method (17 types)

[0157] Actuator motion (19 types)

[0158] Nozzle refill method (4 types)

[0159] Method of restricting back-flow through inlet (10 types)

[0160] Nozzle clearing method (9 types)

[0161] Nozzle plate construction (9 types)

[0162] Drop ejection direction (5 types)

[0163] Ink type (7 types)

[0164] The complete eleven dimensional table represented by these axes contains 36.9 billion possible configurations of inkjet nozzle. While not all of the possible combinations result in a viable ink-jet technology, many million configurations are viable. It is clearly impractical to elucidate all of the possible configurations. Instead, certain inkjet types have been investigated in detail. These are designated IJ01 to IJ45 above.

[0165] Other inkjet configurations can readily be derived from these forty-five examples by substituting alternative configurations along one or more of the eleven axes. Most of the IJ01 to IJ45 examples can be made into inkjet print heads with characteristics superior to any currently available inkjet technology.

[0166] Where there are prior art examples known to the inventor, one or more of these examples are listed in the examples column of the tables below. The IJ01 to IJ45 series are also listed in the examples column. In some cases, a printer may be listed more than once in a table, where it shares characteristics with more than one entry.

[0167] Suitable applications include: Home printers, Office network printers, Short run digital printers, Commercial print systems, Fabric printers, Pocket printers, Internet WWW printers, Video printers, Medical imaging, Wide format printers, Notebook PC printers, Fax machines, Industrial printing systems, Photocopiers, Photographic minilabs etc.

[0168] The information associated with the aforementioned eleven dimensional matrix are set out in the following tables. Description Advantages Disadvantages Examples ACTUATOR MECHANISM (APPLIED ONLY TO SELECTED INK DROPS) Actuator Mech- anism Thermal An electrothermal heater heats the ink to Large force generated High power Canon Bubblejet bubble above boiling point, transferring Simple construction Ink carrier limited to water 1979 Endo et significant heat to the aqueous ink. A No moving parts Low efficiency al GB patent bubble nucleates and quickly forms, Fast operation High temperatures required 2,007,162 expelling the ink. Small chip area required for High mechanical stress Xerox heater-in-pit The efficiency of the process is low, with actuator Unusual materials required 1990 Hawkins et al typically less than 0.05% of the electrical Large drive transistors U.S. Pat. No. energy being transformed into kinetic Cavitation causes actuator failure 4,899,181 Hewlett- energy of the drop. Kogation reduces bubble formation Packard TIJ Large print heads are difficult to fabricate 1982 Vaught et al U.S. Pat. No. 4,490,728 Piezo- A piezoelectric crystal such as lead Low power consumption Very large area required for actuator Kyser et al U.S. electric lanthanum zirconate (PZT) is electrically Many ink types can be used Difficult to integrate with electronics Pat. No. 3,946,398 activated, and either expands, shears, or Fast operation High voltage drive transistors required Zoltan U.S. Pat. No. bends to apply pressure to the ink, High efficiency Full pagewidth print heads impractical 3,683,212 1973 ejecting drops. due to actuator size Stemme U.S. Pat. No. Requires electrical poling in high field 3,747,120 Epson strengths during manufacture Stylus Tektronix IJ04 Electro- An electric field is used to activate Low power consumption Low maximum strain (approx. 0.01%) Seiko Epson, strictive electrostriction in relaxor materials such Many ink types can be used Large area required for actuator due to Usui et all as lead lanthanum zirconate titanate Low thermal expansion low strain JP 253401/96 IJ04 (PLZT) or lead magnesium niobate Electric field strength Response speed is marginal (˜10 μs) (PMN). required (approx. High voltage drive transistors required 3.5 V/μm) can be Full pagewidth print heads impractical generated without due to actuator size difficulty Does not require electrical poling Ferro- An electric field is used to induce a Low power consumption Difficult to integrate with electronics IJ04 electric phase transition between the Many ink types can be used Unusual materials such as PLZSnT are antiferroelectric (AFE) and ferroelectric Fast operation (<1 μs) required (FE) phase. Perovskite materials such as Relatively high longitudinal Actuators require a large area tin modified lead lanthanum zirconate strain titanate (PLZSnT) exhibit large strains of High efficiency up to 1% associated with the AFE to FE Electric field strength of phase transition. around 3 V/μm can be readily provided Electro- Conductive plates are separated by a Low power consumption Difficult to operate electrostatic devices IJ02, IJ04 static compressible or fluid dielectric (usually Many ink types can be used in an aqueous environment plates air). Upon application of a voltage, the Fast operation The electrostatic actuator will normally plates attract each other and displace ink, need to be separated from the ink causing drop ejection. The conductive Very large area required to achieve high plates may be in a comb or honeycomb forces structure, or stacked to increase the High voltage drive transistors may be surface area and therefore the force. required Full pagewidth print heads are not competitive due to actuator size Electro- A strong electric field is applied to the Low current consumption High voltage required 1989 Saito et al, U.S. static ink, whereupon electrostatic attraction Low temperature May be damaged by sparks due to air Pat. No. 4,799,068 pull on accelerates the ink towards the print breakdown 1989 Miura et al, ink medium. Required field strength increases as the U.S. Pat. No. drop size decreases 4,810,954 High voltage drive transistors required Tone-jet Electrostatic field attracts dust Perma- An electromagnet directly attracts a Low power consumption Complex fabrication IJ07, IJ10 nent permanent magnet, displacing ink and Many ink types can be used Permanent magnetic material such as magnet causing drop ejection. Rare earth Fast operation Neodymium Iron Boron (NdFeB) electro- magnets with a field strength around 1 High efficiency required. magnetic Tesla can be used. Examples are: Easy extension from single High local currents required Samarium Cobalt (SaCo) and magnetic nozzles to pagewidth print Copper metalization should be used for materials in the neodymium iron boron heads long electromigration lifetime and low family (NdFeB, NdDyFeBNb, resistivity NdDyFeB, etc) Pigmented inks are usually infeasible Operating temperature limited to the Curie temperature (around 540 K) Soft A solenoid induced a magnetic field in a Low power consumption Complex fabrication IJ01, IJ05, IJ08, magnetic soft magnetic core or yoke fabricated Many ink types can be used Materials not usually present in a CMOS IJ10, IJ12, IJ14, core from a ferrous material such as Fast operation fab such as NiFe, CoNiFe, or CoFe are IJ15, IJ17 electro- electroplated iron alloys such as CoNiFe High efficiency required magnetic [1], CoFe, or NiFe alloys. Typically, the Easy extension from single High local currents required soft magnetic material is in two parts, nozzles to pagewidth print Copper metalization should be used for which are normally held apart by a heads long electromigration lifetime and low spring. When the solenoid is actuated, resistivity the two parts attract, displacing the ink. Electroplating is required High saturation flux density is required (2.0-2.1 T is achievable with CoNiFe [1]) Magnetic The Lorenz force acting on a current Low power consumption Force acts as a twisting motion IJ06, IJ11, IJ13, Lorenz carrying wire in a magnetic field is Many ink types can be used Typically, only a quarter of the solenoid IJ16 force utilized. Fast operation length provides force in a useful direction This allows the magnetic field to be High efficiency High local currents required supplied externally to the print head, for Easy extension from single Copper metalization should be used for example with rare earth permanent nozzles to pagewidth print long electromigration lifetime and low magnets. heads resistivity Only the current carrying wire need be Pigmented inks are usually infeasible fabricated on the print-head, simplifying materials requirements. Magneto- The actuator uses the giant Many ink types can be used Force acts as a twisting motion Fischenbeck, U.S. striction magnetostrictive effect of materials such Fast operation Unusual materials such as Terfenol-D are Pat. No. 4,032,929 as Terfenol-D (an alloy of terbium, Easy extension from single required IJ25 dysprosium and iron developed at the nozzles to pagewidth print High local currents required Naval Ordnance Laboratory, hence Ter- heads Copper metalization should be used for Fe-NOL). For best efficiency, the High force is available long electromigration lifetime and low actuator should be pre-stressed to resistivity approx. 8 MPa. Pre-stressing may be required Surface Ink under positive pressure is held in a Low power consumption Requires supplementary force to effect Silverbrook, tension nozzle by surface tension. The surface Simple construction drop separation EP 0771 658 reduction tension of the ink is reduced below the No unusual materials Requires special ink surfactants A2 and related bubble threshold, causing the ink to required in fabrication Speed may be limited by surfactant patent applications egress from the nozzle. High efficiency properties Easy extension from single nozzles to pagewidth print heads Viscosity The ink viscosity is locally reduced to Simple construction Requires supplementary force to effect Silverbrook, reduction select which drops are to be ejected. A No unusual materials drop separation EP 0771 658 viscosity reduction can be achieved required in fabrication Requires special ink viscosity properties A2 and related electrothermally with most inks, but Easy extension from single High speed is difficult to achieve patent applications special inks can be engineered for a nozzles to pagewidth print Requires oscillating ink pressure 100:1 viscosity reduction. heads A high temperature difference (typically 80 degrees) is required Acoustic An acoustic wave is generated and Can operate without a Complex drive circuitry 1993 Hadimioglu et focussed upon the drop ejection region. nozzle plate Complex fabrication al, EUP 550,192 Low efficiency 1993 Elrod et al, EUP Poor control of drop position 572,220 Poor control of drop volume Thermo- An actuator which relies upon Low power consumption Efficient aqueous operation requires a IJ03, IJ09, IJ17, elastic differential thermal expansion upon Many ink types can be used thermal insulator on the hot side IJ18, IJ19, IJ20, bend Joule heating is used. Simple planar fabrication Corrosion prevention can be difficult IJ21, IJ22, IJ23, actuator Small chip area required for Pigmented inks may be infeasible, as IJ24, IJ27, IJ28, each actuator pigment particles may jam the bend IJ29, IJ30, IJ31, Fast operation actuator IJ32, IJ33, IJ34, High efficiency IJ35, IJ36, IJ37, CMOS compatible voltages IJ38, IJ39, and currents IJ40, IJ41 Standard MEMS processes can be used Easy extension from single nozzles to pagewidth print heads High A material with a very high coefficient of High force can be generated Requires special material (e.g. PTFE) IJ09, IJ17, IJ18, CTE thermal expansion (CTE) such as PTFE is a candidate for low Requires a PTFE deposition process, IJ20, IJ21, IJ22, thermo- polytetrafluoroethylene (PTFE) is used. dielectric constant which is not yet standard in ULSI fabs IJ23, IJ24, IJ27, elastic As high CTE materials are usually non- insulation in ULSI PTFE deposition cannot be followed with IJ28, IJ29, IJ30, actuator conductive, a heater fabricated from a Very low power high temperature (above 350° C.) IJ31, IJ42, conductive material is incorporated. consumption Many ink processing IJ43, IJ44 A 50 μm long PTFE bend actuator with types can be used Simple Pigmented inks may be infeasible, as polysilicon heater and 15 mW power planar fabrication Small pigment particles may jam the bend input can provide 180 μN force and 10 μm chip area required for actuator deflection. Actuator motions include: each actuator Fast Bend operation High efficiency Push CMOS compatible voltages Buckle and currents Rotate Easy extension from single nozzles to pagewidth print heads Conduc- A polymer with a high coefficient of High force can be generated Requires special materials development IJ24 tive thermal expansion (such as PTFE) is Very low power (High CTE conductive polymer) polymer doped with conducting substances to consumption Many ink Requires a PTFE deposition process, thermo- increase its conductivity to about 3 types can be used Simple which is not yet standard in ULSI fabs elastic orders of magnitude below that of planar fabrication Small PTFE deposition cannot be followed with actuator copper. The conducting polymer expands chip area required for high temperature (above 350° C.) when resistively heated. each actuator Fast processing Examples of conducting dopants include: operation High efficiency Evaporation and CVD deposition Carbon nanotubes CMOS compatible voltages techniques cannot be used Metal fibers and currents Pigmented inks may be infeasible, as Conductive polymers such as doped Easy extension from single pigment particles may jam the bend polythiophene nozzles to pagewidth print actuator Carbon granules heads Shape A shape memory alloy such as TiNi (also High force is available Fatigue limits maximum number of IJ26 memory known as Nitinol-Nickel Titanium alloy (stresses of hundreds of cycles alloy developed at the Naval Ordnance MPa) Large strain is Low strain (1%) is required to extend Laboratory) is thermally switched available (more than 3%) fatigue resistance between its weak martensitic state and its High corrosion resistance Cycle rate limited by heat removal high stiffness austenic state. The shape of Simple construction Requires unusual materials (TiNi) the actuator in its martensitic state is Easy extension from single The latent heat of transformation must be deformed relative to the austenic shape. nozzles to pagewidth print provided The shape change causes ejection of a heads High current operation drop. Low voltage operation Requires pre-stressing to distort the martensitic state Linear Linear magnetic actuators include the Linear Magnetic actuators Requires unusual semiconductor IJ12 Magnetic Linear Induction Actuator (LIA), Linear can be constructed materials such as soft magnetic alloys Actuator Permanent Magnet Synchronous with high thrust, long (e.g. CoNiFe [1]) Actuator (LPMSA), Linear Reluctance travel, and high efficiency Some varieties also require permanent Synchronous Actuator (LRSA), Linear using planar semiconductor magnetic materials such as Neodymium Switched Reluctance Actuator (LSRA), fabrication techniques iron boron (NdFeB) and the Linear Stepper Actuator (LSA). Long actuator travel is Requires complex multi-phase drive available circuitry Medium force is available High current operation Low voltage operation BASIC OPERATION MODE Opera- tional mode Actuator This is the simplest mode of operation: Simple operation Drop repetition rate is usually limited to Thermal inkjet directly the actuator directly supplies sufficient No external fields required less than 10 KHz. However, this is not Piezoelectric inkjet pushes kinetic energy to expel the drop. The Satellite drops can be fundamental to the method, but is related IJ01, IJ02, IJ03, IJ04 ink drop must have a sufficient velocity to avoided if drop velocity is to the refill method normally used IJ05, IJ06, IJ07, IJ09 overcome the surface tension. less than 4 m/s Can be All of the drop kinetic energy must be IJ11, IJ12, IJ14, IJ16 efficient, depending upon provided by the actuator IJ20, IJ22, IJ23, IJ24 the actuator used Satellite drops usually form if drop IJ25, IJ26, IJ27, IJ28 velocity is greater than 4.5 m/s IJ29, IJ30, IJ31, IJ32 IJ33, IJ34, IJ35, IJ36 IJ37, IJ38, IJ39, IJ40 IJ41, IJ42, IJ43, IJ44 Proximity The drops to be printed are selected by Very simple print head Requires close proximity between the Silverbrook, EP 0771 some manner (e.g. thermally induced fabrication can be used print head and the print media or transfer 658 A2 and related surface tension reduction of pressurized The drop selection means roller patent applications ink). Selected does not need May require two drops are separated from to provide the print heads printing the ink in the nozzle by contact with the energy required to separate alternate rows of the image print medium or a transfer roller. the drop from the nozzle Monolithic color print heads are difficult Electro- The drops to be printed are selected by Very simple print head Requires very high electrostatic field Silverbrook, EP 0771 static some manner (e.g. thermally induced fabrication can be used Electrostatic field for small nozzle sizes is 658 A2 and related pull on surface tension reduction of pressurized The drop selection means above air breakdown patent applications ink ink). Selected drops does not need Electrostatic field Tone- are separated from to provide the may attract dust Jet the ink in the nozzle by a strong electric energy required to separate field. the drop from the nozzle Magnetic The drops to be printed are selected by Very simple print head Requires magnetic ink Silverbrook, EP 0771 pull on some manner (e.g. thermally induced fabrication can be used Ink colors other than black are difficult 658 A2 and related ink surface tension reduction of pressurized The drop selection means Requires very high magnetic fields patent applications ink). Selected drops are separated from does not need to provide the ink in the nozzle by a strong the energy required magnetic field acting on the magnetic to separate the drop ink. from the nozzle Shutter The actuator moves a shutter to block ink High speed (>50 KHz) Moving parts are required IJ13, IJ17, IJ21 flow to the nozzle. The ink pressure is operation can be achieved Requires ink pressure modulator pulsed at a multiple of the drop ejection due to reduced refill time Friction and wear must be considered frequency. Drop timing can be very Stiction is possible accurate The actuator energy can be very low Shut- The actuator moves a shutter to block ink Actuators with small travel Moving parts are required IJ08, IJ15, IJ18, IJ19 tered flow through a grill to the nozzle. The can be used Requires ink pressure modulator grill shutter movement need only be equal to Actuators with small force Friction and wear must be considered the width of the grill holes. can be used Stiction is possible High speed (>50 KHz) operation can be achieved Pulsed A pulsed magnetic field attracts an ‘ink Extremely low energy Requires an external pulsed magnetic IJ10 magnetic pusher’ at the drop ejection frequency. operation is possible field pull on An actuator controls a catch, which No heat dissipation Requires special materials for both the ink prevents the ink pusher from moving problems actuator and the ink pusher pusher when a drop is not to be ejected. Complex construction AUXILIARY MECHANISM (APPLIED TO ALL NOZZLES) Auxiliary Mecha- nism None The actuator directly fires the ink drop, Simplicity of construction Drop ejection energy must be supplied by Most inkjets, and there is no external field or other Simplicity of operation individual nozzle actuator including piezoelectric mechanism required. Small physical size and thermal bubble. IJ01-IJ07, IJ09, IJ11 IJ12, IJ14, IJ20, IJ22 IJ23-IJ45 Oscillat- The ink pressure oscillates, providing Oscillating ink pressure can Requires external ink pressure oscillator Silverbrook, EP 0771 ing ink much of the drop ejection energy. The provide a refill pulse, Ink pressure phase and amplitude must be 658 A2 and related pressure actuator selects which drops are to be allowing higher operating carefully controlled patent applications (includ- fired by selectively blocking or enabling speed Acoustic reflections in the ink chamber IJ08, IJ13, IJ15, IJ17 ing nozzles. The ink pressure oscillation may The actuators may operate must be designed for IJ18, IJ19, IJ21 acoustic be achieved by vibrating the print head, with much lower energy stimula- or preferably by an actuator in the ink Acoustic lenses can be used tion) supply. to focus the sound on the nozzles Media The print head is placed in close Low power Precision assembly required Silverbrook, EP 0771 proximity proximity to the print medium. Selected High accuracy Paper fibers may cause problems 658 A2 and related drops protrude from the print head Simple print head Cannot print on rough substrates patent applications further than unselected drops, and construction contact the print medium. The drop soaks into the medium fast enough to cause drop separation. Transfer Drops are printed to a transfer roller High accuracy Bulky Silverbrook, EP 0771 roller instead of straight to the print medium. A Wide range of print Expensive 658 A2 and related transfer roller can also be used for substrates can be used Complex construction patent applications proximity drop separation. Ink can be dried on the Tektronix hot melt transfer roller piezoelectric inkjet Any of the IJ series Electro- An electric field is used to accelerate Low power Field strength required for separation of Silverbrook, EP 0771 static selected drops towards the print medium. Simple print head small drops is near or above air 658 A2 and related construction breakdown patent applications Tone-Jet Direct A magnetic field is used to accelerate Low power Requires magnetic ink Silverbrook, EP 0771 magnetic selected drops of magnetic ink towards Simple print head Requires strong magnetic field 658 A2 and related field the print medium. construction patent applications Cross The print head is placed in a constant Does not require magnetic Requires external magnet IJ06, IJ16 magnetic magnetic field. The Lorenz force in a materials to be integrated in Current densities may be high, resulting field current carrying wire is used to move the the print head in electromigration problems actuator. manufacturing process Pulsed A pulsed magnetic field is used to Very low power Complex print head construction IJ10 magnetic cyclically attract a paddle, which pushes operation is possible Magnetic materials required in print head field on the ink. A small actuator moves a Small print head size catch, which selectively prevents the paddle from moving. ACTUATOR AMPLIFICATION OR MODIFICATION METHOD Actuator amplifi- cation None No actuator mechanical amplification is Operational simplicity Many actuator mechanisms have Thermal Bubble Inkjet used. The actuator directly drives the insufficient travel, or insufficient force, to IJ01, IJ02, IJ06, IJ07 drop ejection process. efficiently drive the drop ejection process IJ16, IJ25, IJ26 Differen- An actuator material expands more on Provides greater travel in a High stresses are involved Piezoelectric tial one side than on the other. The reduced print head area Care must be taken that the materials do IJ03, IJ09, IJ17-IJ24 expansion expansion may be thermal, piezoelectric, The bend actuator converts not delaminate IJ27, IJ29-IJ39, IJ42, bend magnetostrictive, or other mechanism. a high force low travel Residual bend resulting from high IJ43, IJ44 actuator actuator mechanism to temperature or high stress during high travel, lower formation force mechanism. Transient A trilayer bend actuator where the two Very good temperature High stresses are involved IJ40, IJ41 bend outside layers are identical. This cancels stability Care must be taken that the materials do actuator bend due to ambient temperature and High speed, as a new drop not delaminate residual stress. The actuator only can be fired before heat responds to transient heating of one side dissipates or the other. Cancels residual stress of formation Actuator A series of thin actuators are stacked. Increased travel Increased fabrication complexity Some piezoelectric ink stack This can be appropriate where actuators Reduced drive voltage Increased possibility of short circuits due jets require high electric field strength, such to pinholes IJ04 as electrostatic and piezoelectric actuators. Multiple Multiple smaller actuators are used Increases the force Actuator forces may not add linearly, IJ12, IJ13, IJ18, IJ20 actuators simultaneously to move the ink. Each available from an actuator reducing efficiency IJ22, IJ28, IJ42, IJ43 actuator need provide only a portion of Multiple actuators can be the force required. positioned to control ink flow accurately Linear A linear spring is used to transform a Matches low travel actuator Requires print head area for the spring IJ15 Spring motion with small travel and high force with higher travel into a longer travel, lower force motion. requirements Non-contact method of motion transformation Reverse The actuator loads a spring. When the Better coupling to the ink Fabrication complexity IJ05, IJ11 spring actuator is turned off, the spring releases. High stress in the spring This can reverse the force/distance curve of the actuator to make it compatible with the force/time requirements of the drop ejection. Coiled A bend actuator is coiled to provide Increases travel Generally restricted to planar IJ17, IJ21, IJ34, IJ35 actuator greater travel in a reduced chip area. Reduces chip area implementations due to extreme Planar implementations are fabrication difficulty in other orientations. relatively easy to fabricate. Flexure A bend actuator has a small region near Simple means of increasing Care must be taken not to exceed the IJ10, IJ19, IJ33 bend the fixture point, which flexes much travel of a bend actuator elastic limit in the flexure area actuator more readily than the remainder of the Stress distribution is very uneven actuator. The actuator flexing is Difficult to accurately model with finite effectively converted from an even element analysis coiling to an angular bend, resulting in greater travel of the actuator tip. Gears Gears can be used to increase travel at Low force, low travel Moving parts are required IJ13 the expense of duration. Circular gears, actuators can be used Several actuator cycles are required rack and pinion, ratchets, and other Can be fabricated using More complex drive electronics gearing methods can be used. standard surface MEMS Complex construction processes Friction, friction, and wear are possible Catch The actuator controls a small catch. The Very low actuator energy Complex construction IJ10 catch either enables or disables Very small actuator size Requires external force movement of an ink pusher that is Unsuitable for pigmented inks controlled in a bulk manner. Buckle A buckle plate can be used to change a Very fast movement Must stay within elastic limits of the S. Hirata et al, “An plate slow actuator into a fast motion. It can achievable materials for long device life Ink-jet Head . . . ”, also convert a high force, low travel High stresses involved Proc. IEEE MEMS, actuator into a high travel, medium force Generally high power requirement Feb. 1996, pp motion. 418-423. IJ18, IJ27 Tapered A tapered magnetic pole can increase Linearizes the magnetic Complex construction IJ14 magnetic travel at the expense of force. force/distance curve pole Lever A lever and fulcrum is used to transform Matches low travel actuator High stress around the fulcrum IJ32, IJ36, IJ37 a motion with small travel and high force with higher travel into a motion with longer travel and requirements lower force. The lever can also reverse Fulcrum area has no linear the direction of travel. movement, and can be used for a fluid seal Rotary The actuator is connected to a rotary High mechanical advantage Complex construction IJ28 impeller impeller. A small angular deflection of The ratio of force to Unsuitable for pigmented inks the actuator results in a rotation of the travel of the actuator can impeller vanes, which push the ink be matched to the nozzle against stationary vanes and out of the requirements by varying nozzle. the number of impeller vanes Acoustic A refractive or diffractive (e.g. zone No moving parts Large area required 1993 Hadimioglu et lens plate) acoustic lens is used to concentrate Only relevant for acoustic ink jets al, EUP 550,192 sound waves. 1993 Elrod et al, EUP 572,220 Sharp A sharp point is used to concentrate an Simple construction Difficult to fabricate using standard VLSI Tone-jet conduc- electrostatic field. processes for a surface ejecting ink-jet tive Only relevant for electrostatic ink jets point ACTUATOR MOTION Actuator motion Volume The volume of the actuator changes, Simple construction in the High energy is typically required to Hewlett-Packard expan- pushing the ink in all directions. case of thermal ink jet achieve volume expansion. This leads to Thermal Inkjet sion thermal stress, cavitation, and kogation in Canon Bubblejet thermal ink jet implementations Linear, The actuator moves in a direction normal Efficient coupling to ink High fabrication complexity may be IJ01, IJ02, IJ04, IJ07 normal to the print head surface. The nozzle is drops ejected normal to the required to achieve perpendicular motion IJ11, IJ14 to chip typically in the line of movement. surface surface Linear, The actuator moves parallel to the print Suitable for planar Fabrication complexity IJ12, IJ13, IJ15, IJ33, parallel head surface. Drop ejection may still be fabrication Friction IJ34, IJ35, IJ36 to chip normal to the surface. Stiction surface Mem- An actuator with a high force but small The effective area of the Fabrication complexity 1982 Howkins brane area is used to push a stiff membrane that actuator becomes the Actuator size U.S. Pat. No. push is in contact with the ink. membrane area Difficulty of integration in a VLSI 4,459,601 process Rotary The actuator causes the rotation of some Rotary levers may be Device complexity IJ05, IJ08, IJ13, IJ28 element, such a grill or impeller used to increase travel May have friction at a pivot point Small chip area requirements Bend The actuator bends when energized. This A very small change in Requires the actuator to be made from at 1970 Kyser et al may be due to differential thermal dimensions can be least two distinct layers, or to have a U.S. Pat. No. expansion, piezoelectric expansion, converted to a large thermal difference across the actuator 3,946,398 magnetostriction, or other form of motion. 1973 Stemme relative dimensional change. U.S. Pat. No. 3,747,120 IJ03, IJ09, IJ10, IJ19 IJ23, IJ24, IJ25, IJ29 IJ30, IJ31, IJ33, IJ34 IJ35 Swivel The actuator swivels around a central Allows operation where the Inefficient coupling to the ink motion IJ06 pivot. This motion is suitable where there net linear force on the are opposite forces applied to opposite paddle is zero Small sides of the paddle, e.g. Lorenz force. chip area requirements Straight- The actuator is normally bent, and Can be used with shape Requires careful balance of stresses to IJ26, IJ32 en straightens when energized. memory alloys where the ensure that the quiescent bend is accurate austenic phase is planar Double The actuator bends in one direction when One actuator can be used Difficult to make the drops ejected by IJ36, IJ37, IJ38 bend one element is energized, and bends the to power two nozzles. both bend directions identical. other way when another element is Reduced chip size. A small efficiency loss compared to energized. Not sensitive to ambient equivalent single bend actuators. temperature Shear Energizing the actuator causes a shear Can increase the Not readily applicable to other 1985 Fishbeck motion in the actuator material. effective travel of actuator mechanisms U.S. Pat. No. piezoelectric actuators 4,584,590 Radial The actuator squeezes an ink reservoir, Relatively easy to High force required 1970 Zoltan constric- forcing ink from a constricted nozzle. fabricate single nozzles Inefficient U.S. Pat. No. tion from glass tubing as Difficult to integrate with VLSI 3,683,212 macroscopic structures processes Coil/ A coiled actuator uncoils or coils more Easy to fabricate as a Difficult to fabricate for non-planar IJ17, IJ21, IJ34, uncoil tightly. The motion of the free end of the planar VLSI process devices IJ35 actuator ejects the ink. Small area required, Poor out-of-plane stiffness therefore low cost Bow The actuator bows (or buckles) in the Can increase the speed Maximum travel is constrained IJ16, IJ18, IJ27 middle when energized. of travel High force required Mechanically rigid Push- Two actuators control a shutter. One The structure is pinned at Not readily suitable for inkjets which IJ18 Pull actuator pulls the shutter, and the other both ends, so has a high directly push the ink pushes it. out-of-plane rigidity Curl A set of actuators curl inwards to reduce Good fluid flow to the Design complexity IJ20, IJ42 inwards the volume of ink that they enclose. region behind the actuator increases efficiency Curl A set of actuators curl outwards, Relatively simple Relatively large chip area IJ43 outwards pressurizing ink in a chamber construction surrounding the actuators, and expelling ink from a nozzle in the chamber. Iris Multiple vanes enclose a volume of ink. High efficiency High fabrication complexity IJ22 These simultaneously rotate, reducing Small chip area Not suitable for pigmented inks the volume between the vanes. Acoustic The actuator vibrates at a high frequency. The actuator can be Large area required for efficient 1993 Hadimioglu vibration physically distant from operation at useful frequencies et al, EUP the ink Acoustic coupling and crosstalk 550,192 Complex drive circuitry 1993 Elrod et al, Poor control of drop volume and EUP 572,220 position None In various ink jet designs the actuator No moving parts Various other tradeoffs are required to Silverbrook, does not move. eliminate moving parts EP 0771 658 A2 and related patent applications Tone-jet NOZZLE REFILL METHOD Nozzle refill method Surface After the actuator is energized, it Fabrication simplicity Low speed Thermal inkjet tension typically returns rapidly to its normal Operational simplicity Surface tension force relatively small Piezoelectric inkjet position. This rapid return sucks in air compared to actuator force IJ01-IJ07, IJ10-IJ14 through the nozzle opening. The ink Long refill time usually dominates the IJI6, IJ20, IJ22-IJ45 surface tension at the nozzle then exerts a total repetition rate small force restoring the meniscus to a minimum area. Shut- Ink to the nozzle chamber is provided at High speed Requires common ink pressure oscillator IJ08, IJ13, IJ15, IJ17 tered a pressure that oscillates at twice the Low actuator energy, as the May not be suitable for pigmented inks IJ18, IJ19, IJ21 oscillat- drop ejection frequency. When a drop is actuator need only open or ing to be ejected, the shutter is opened for 3 close the shutter, instead of ink half cycles: drop ejection, actuator ejecting the ink drop pressure return, and refill. Refill After the main actuator has ejected a High speed, as the nozzle is Requires two independent actuators per IJ09 actuator drop a second (refill) actuator is actively refilled nozzle energized. The refill actuator pushes ink into the nozzle chamber. The refill actuator returns slowly, to prevent its return from emptying the chamber again. Positive The ink is held a slight positive pressure. High refill rate, therefore a Surface spill must be prevented Silverbrook, EP 0771 ink After the ink drop is ejected, the nozzle high drop repetition rate is Highly hydrophobic print head surfaces 658 A2 and related pressure chamber fills quickly as surface tension possible are required patent applications and ink pressure both operate to refill the Alternative for: nozzle. IJ01-IJ07, IJ10-IJ14 IJ16, IJ20, IJ22-IJ45 METHOD OF RESTRICTING BACK-FLOW THROUGH INLET Inlet back- flow restric- tion method Long The ink inlet channel to the nozzle Design simplicity Restricts refill rate Thermal inkjet inlet chamber is made long and relatively Operational simplicity May result in a relatively large chip area Piezoelectric inkjet channel narrow, relying on viscous drag to reduce Reduces crosstalk Only partially effective IJ42, IJ43 inlet back-flow. Positive The ink is under a positive pressure, so Drop selection and Requires a method (such as a nozzle Silverbrook, EP ink that in the quiescent state some of the ink separation forces can be rim or effective hydrophobizing, or 0771 658 A2 and pressure drop already protrudes from the nozzle. reduced both) to prevent flooding of the related patent This reduces the pressure in the nozzle Fast refill time ejection surface of the print head. applications chamber which is required to eject a Possible operation certain volume of ink. The reduction in of the following: chamber pressure results in a reduction IJ01-IJ07, IJ09-IJ12 in ink pushed out through the inlet. IJ14, IJ16, IJ20, IJ22, IJ23-IJ34, IJ36-IJ41 IJ44 Baffle One or more baffles are placed in the The refill rate is not as Design complexity HP Thermal Ink inlet ink flow. When the actuator is restricted as the long May increase fabrication complexity Jet energized, the rapid ink movement inlet method. (e.g. Tektronix hot melt Piezoelectric Tektronix creates eddies which restrict the flow Reduces crosstalk print heads). piezoelectric ink through the inlet. The slower refill jet process is unrestricted, and does not result in eddies. Flexible In this method recently disclosed by Significantly reduces Not applicable to most inkjet Canon flap Canon, the expanding actuator (bubble) back-flow for edge- configurations restricts pushes on a flexible flap that restricts the shooter thermal ink jet Increased fabrication complexity inlet inlet. devices Inelastic deformation of polymer flap results in creep over extended use Inlet A filter is located between the ink inlet Additional advantage of Restricts refill rate IJ04, IJ12, IJ24, filter and the nozzle chamber. The filter has a ink filtration May result in complex construction IJ27 multitude of small holes or slots, Ink filter may be IJ29, IJ30 restricting ink flow. The filter also fabricated with no removes particles which may block the additional process steps nozzle. Small The ink inlet channel to the nozzle Design simplicity Restricts refill rate IJ02, IJ37, IJ44 inlet chamber has a substantially smaller cross May result in a relatively large chip com- section than that of the nozzle, resulting area pared in easier ink egress out of the nozzle than Only partially effective to out of the inlet. nozzle Inlet A secondary actuator controls the Increases speed of the Requires separate refill actuator and drive IJ09 shutter position of a shutter, closing off the ink ink-jet print head circuit inlet when the main actuator is operation energized. The The method avoids the problem of inlet Back-flow problem is Requires careful design to minimize the IJ01, IJ03, IJ05, IJ06 inlet is back-flow by arranging the ink-pushing eliminated negative pressure behind the paddle IJ07, IJ10, IJ11, IJ14 located surface of the actuator between the inlet IJ16, IJ22, IJ23, IJ25 behindthe and the nozzle. IJ28, IJ31, IJ32, IJ33 ink- IJ34, IJ35, IJ36, IJ39 pushing IJ40, IJ41 surface Part The actuator and a wall of the ink Significant reductions in Small increase in fabrication complexity IJ07, IJ20, IJ26, IJ38 of the chamber are arranged so that the motion back-flow can be achieved actuator of the actuator closes off the inlet. Compact designs possible moves to shut off the inlet Nozzle In some configurations of ink jet, there is Ink back-flow problem is None related to ink back-flow on Silverbrook, EP 0771 actuator no expansion or movement of an actuator eliminated actuation 658 A2 and related does which may cause ink back-flow through patent applications not the inlet. Valve-jet result Tone-jet in ink IJ08, IJ13, IJ15, IJ17 back- IJ18, IJ19, IJ21 flow NOZZLE CLEARING METHOD Nozzle Clearing method Normal All of the nozzles are fired periodically, No added complexity May not be sufficient to displace dried Most ink jet systems nozzle before the ink has a chance to dry. When on the print head ink IJ01-IJ07, IJ09-IJ12 firing not in use the nozzles are sealed (capped) IJ14, IJ16, IJ20, IJ22 against air. IJ23-IJ34, IJ36-IJ45 The nozzle firing is usually performed during a special clearing cycle, after first moving the print head to a cleaning station. Extra In systems which heat the ink, but do not Can be highly effective if Requires higher drive voltage for clearing Silverbrook, EP 0771 power boil it under normal situations, nozzle the heater is adjacent May require larger drive transistors 658 A2 and related to ink clearing can be achieved by over- to the nozzle patent applications heater powering the heater and boiling ink at the nozzle. Rapid The actuator is fired in rapid succession. Does not require extra drive Effectiveness depends substantially upon May be used with: succes- In some configurations, this may cause circuits on the print head the configuration of the inkjet nozzle IJ01-IJ07, IJ09-IJ11 sion of heat build-up at the nozzle which boils Can be readily controlled IJ14, IJ16, IJ20, IJ22 actuator the ink, clearing the nozzle. In other and initiated by IJ23-IJ25, IJ27-IJ34 pulses situations, it may cause sufficient digital logic IJ36-IJ45 vibrations to dislodge clogged nozzles. Extra Where an actuator is not normally driven A simple solution where Not suitable where there is a hard limit to May be used with: power to the limit of its motion, nozzle clearing applicable actuator movement IJ03, IJ09, IJ16, IJ20 to ink may be assisted by providing an IJ23, IJ24, IJ25, IJ27 pushing enhanced drive signal to the actuator. IJ29, IJ30, IJ31, IJ32 actuator IJ39, IJ40, IJ41, IJ42 IJ43, IJ44, IJ45 Acoustic An ultrasonic wave is applied to the ink A high nozzle clearing High implementation cost if system does IJ08, IJ13, IJ15, IJ17 reso- chamber. This wave is of an appropriate capability can be achieved not already include an acoustic actuator IJ18, IJ19, IJ21 nance amplitude and frequency to cause May be implemented at sufficient force at the nozzle to clear very low cost in systems blockages. This is easiest to achieve if which already include the ultrasonic wave is at a resonant acoustic actuators frequency of the ink cavity. Nozzle A microfabricated plate is pushed against Can clear severely clogged Accurate mechanical alignment is Silverbrook, EP 0771 clearing the nozzles. The plate has a post for nozzles required 658 A2 and related plate every nozzle. The array of posts Moving parts are required patent applications There is risk of damage to the nozzles Accurate fabrication is required Ink The pressure of the ink is temporarily May be effective where Requires pressure pump or other pressure May be used with all pressure increased so that ink streams from all of other methods cannot actuator IJ series ink jets pulse the nozzles. This may be used in be used Expensive conjunction with actuator energizing. Wasteful of ink Print A flexible ‘blade’ is wiped across the Effective for planar print Difficult to use if print head surface is Many ink jet systems head print head surface. The blade is usually head surfaces non-planar or very fragile wiper fabricated from a flexible polymer, e.g. Low cost Requires mechanical parts rubber or synthetic elastomer. Blade can wear out in high volume print systems Separate A separate heater is provided at the Can be effective where Fabrication complexity Can be used with ink nozzle although the normal drop e-ection other nozzle clearing many IJ series ink jets boiling mechanism does not require it. The methods cannot be used heater heaters do not require individual drive Can be implemented at no circuits, as many nozzles can be cleared additional cost in some simultaneously, and no imaging is inkjet configurations required. NOZZLE PLATE CONSTRUCTION Nozzle plate construc- tion Electro- A nozzle plate is separately fabricated Fabrication simplicity High temperatures and pressures are Hewlett Packard formed from electroformed nickel, and bonded required to bond nozzle plate Thermal Inkjet nickel to the print head chip. Minimum thickness constraints Differential thermal expansion Laser Individual nozzle holes are ablated by an No masks required Each hole must be individually formed Canon Bubblejet ablated intense UV laser in a nozzle plate, which Can be quite fast Special equipment required 1988 Sercel et al., or is typically a polymer such as polyimide Some control over nozzle Slow where there are many thousands of SPIE, Vol. 998 drilled or polysulphone profile is possible nozzles per print head Excimer Beam polymer Equipment required is May produce thin burrs at exit holes Applications, pp. relatively low cost 76-83 1993 Watanabe et al., U.S. Pat. No. 5,208,604 Silicon A separate nozzle plate is High accuracy is attainable Two part construction K. Bean, IEEE micro- micromachined from single crystal High cost Transactions on machined silicon, and bonded to the print head Requires precision alignment Electron Devices, Vol. wafer. Nozzles may be clogged by adhesive ED-25, No. 10, 1978, pp 1185-1195 Xerox 1990 Hawkins et al., U.S. Pat. No. 4,899,181 Glass Fine glass capillaries are drawn from No expensive equipment Very small nozzle sizes are difficult to 1970 Zoltan U.S. capil- glass tubing. This method has been used required form Pat. No. 3,683,212 laries for making individual nozzles, but is Simple to make single Not suited for mass production difficult to use for bulk manufacturing of nozzles print heads with thousands of nozzles. Mono- The nozzle plate is deposited as a layer High accuracy (<1 μm) Requires sacrificial layer under the nozzle Silverbrook, EP 0771 lithic, using standard VLSI deposition Monolithic plate to form the nozzle chamber 658 A2 and related surface techniques. Nozzles are etched in the Low cost Surface may be fragile to the touch patent applications micro- nozzle plate using VLSI lithography and Existing processes can be IJ01, IJ02, IJ04, IJ11 machined etching. used IJ12, IJ17, IJ18, IJ20 using IJ22, IJ24, IJ27, IJ28 VLSI IJ29, IJ30, IJ31, IJ32 litho- IJ33, IJ34, IJ36, IJ37 graphic IJ38, IJ39, IJ40, IJ41 processes IJ42, IJ43, IJ44 Mono- The nozzle plate is a buried etch stop in High accuracy (<1 μm) Requires long etch times IJ03, IJ05, IJ06, IJ07 lithic, the wafer. Nozzle chambers are etched in Monolithic Requires a support wafer IJ08, IJ09, IJ10, IJ13 etched the front of the wafer, and the wafer is Low cost IJ14, IJ15, IJ16, IJ19 through thinned from the back side. Nozzles are No differential expansion IJ21, IJ23, IJ25, IJ26 substrate then etched in the etch stop layer. No Various methods have been tried to No nozzles to become Difficult to control drop position Ricoh 1995 Sekiya et nozzle eliminate the nozzles entirely, to prevent clogged accurately al U.S. Pat. No. plate nozzle clogging. These include thermal Crosstalk problems 5,412,413 bubble mechanisms and acoustic lens 1993 Hadimioglu mechanisms et al EUP 550,192 1993 Elrod et al EUP 572,220 Trough Each drop ejector has a trough through Reduced manufacturing Drop firing direction is sensitive to IJ35 which a paddle moves. There is no complexity wicking. nozzle plate. Monolithic Nozzle The elimination of nozzle holes and No nozzles to become Difficult to control drop position 1989 Saito et al slit replacement by a slit encompassing clogged accurately U.S. Pat. No. instead many actuator positions reduces nozzle Crosstalk problems 4,799,068 of clogging, but increases crosstalk due to indi- ink surface waves vidual nozzles DROP EJECTION DIRECTION Ejection direction Edge Ink flow is along the surface of the chip, Simple construction Nozzles limited to edge Canon Bubblejet (‘edge and ink drops are ejected from the chip No silicon etching High resolution is difficult 1979 Endo et al shooter’) edge. required Fast color printing requires one print GB patent Good heat sinking via head per color 2,007,162 substrate Xerox heater-in- Mechanically strong pit 1990 Hawkins Ease of chip handing et al U.S. Pat. No. 4,899,181 Tone-jet Surface Ink flow is along the surface of the chip, No bulk silicon etching Maximum ink flow is severely Hewlett-Packard (‘roof and ink drops are ejected from the chip required restricted TIJ 1982 Vaught shooter’) surface, normal to the plane of the chip. Silicon can make an et al U.S. Pat. No. effective heat sink 4,490,728 Mechanical strength IJ02, IJ11, IJ12, IJ20 IJ22 Through Ink flow is through the chip, and ink High ink flow Requires bulk silicon etching Silverbrook, EP chip, drops are ejected from the front surface Suitable for pagewidth 0771 658 A2 and forward of the chip. print related patent (‘up High nozzle packing applications shooter’) density therefore low IJ04, IJ17, IJ18, manufacturing cost IJ24 IJ27-IJ45 Through Ink flow is through the chip, and ink High ink flow Requires wafer thinning IJ01, IJ03, IJ05, chip, drops are ejected from the rear surface of Suitable for pagewidth Requires special handling during IJ06 reverse the chip. print manufacture IJ07, IJ08, IJ09, (‘down High nozzle packing IJ10 shooter’) density therefore low IJ13, IJ14, IJ15, manufacturing cost IJ16 IJ19, IJ21, IJ23, IJ25 IJ26 Through Ink flow is through the actuator, which is Suitable for piezoelectric Pagewidth print heads require several Epson Stylus actuator not fabricated as part of the same print heads thousand connections to drive circuits Tektronix hot substrate as the drive transistors. Cannot be manufactured in standard melt piezoelectric CMOS fabs ink jets Complex assembly required INK TYPE Ink type Aqueous, Water based ink which typically Environmentally friendly Slow drying Most existing inkjets dye contains: water, dye, surfactant, No odor Corrosive All IJ series ink jets humectant, and biocide. Bleeds on paper Silverbrook, EP 0771 Modern ink dyes have high water- May strikethrough 658 A2 and related fastness, light fastness Cockles paper patent applications Aqueous, Water based ink which typically Environmentally friendly Slow drying IJ02, IJ04, IJ21, IJ26 pigment contains: water, pigment, surfactant, No odor Corrosive IJ27, IJ30 humectant, and biocide. Reduced bleed Pigment may clog nozzles Silverbrook, EP 0771 Pigments have an advantage in reduced Reduced wicking Pigment may clog actuator mechanisms 658 A2 and related bleed, wicking and strikethrough. Reduced strikethrough Cockles paper patent applications Piezoelectric ink-jets Thermal ink jets (with significant restrictions) Methyl MEK is a highly volatile solvent used for Very fast drying Odorous All IJ series ink jets Ethyl industrial printing on difficult surfaces Prints on various substrates Flammable Ketone such as aluminum cans. such as metals and plastics (MEK) Alcohol based inks can be used where Fast drying Slight odor All IJ series ink jets Alcohol the printer must operate at temperatures Operates at sub-freezing Flammable (ethanol, below the freezing point of water. An temperatures 2- example of this is in-camera consumer Reduced paper cockle butanol, photographic printing. Low cost and others) Phase The ink is solid at room temperature, and No drying time-ink High viscosity Tektronix hot melt change is melted in the print head before jetting. instantly freezes on the Printed ink typically has a ‘waxy’ feel piezoelectric ink jets (hot Hot melt inks are usually wax based, print medium Almost Printed pages may ‘block’ 1989 Nowak U.S. melt) with a melting point around 80° C. After any print medium Ink temperature may be above the curie Pat. No. 4,820,346 jetting the ink freezes almost instantly can be used No paper point of permanent magnets All IJ series ink jets upon contacting the print medium or a cockle occurs No Ink heaters consume power transfer roller. wicking occurs No Long warm-up time bleed occurs No strikethrough occurs Oil Oil based inks are extensively used in High solubility medium for High viscosity: this is a significant All IJ series ink jets offset printing. They have advantages in some dyes limitation for use in inkjets, which usually improved characteristics on paper Does not cockle paper require a low viscosity. Some short chain (especially no wicking or cockle). Oil Does not wick through and multi-branched oils have a soluble dies and pigments are required. paper sufficiently low viscosity. Slow drying Micro- A microemulsion is a stable, self forming Stops ink bleed Viscosity higher than water All IJ series ink jets emulsion emulsion of oil, water, and surfactant. High dye solubility Cost is slightly higher than water based The characteristic drop size is less than Water, oil, and amphiphilic ink 100 nm, and is determined by the soluble dies can be used High surfactant concentration required preferred curvature of the surfactant. Can stabilize pigment (around 5%) suspensions

[0169] Ink Jet Printing

[0170] A large number of new forms of ink jet printers have been developed to facilitate alternative ink jet technologies for the image processing and data distribution system. Various combinations of ink jet devices can be included in printer devices incorporated as part of the present invention. Australian Provisional Patent Applications relating to these ink jets which are specifically incorporated by cross reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. US Patent/ Australian Patent Provisional Application Number Filing Date Title and Filing Date PO8066 15-Jul-97 Image Creation Method and 6,227,652 Apparatus (IJ01) (Jul. 10, 1998) PO8072 15-Jul-97 Image Creation Method and 6,213,588 Apparatus (IJ02) (Jul. 10, 1998) PO8040 15-Jul-97 Image Creation Method and 6,213,589 Apparatus (IJ03) (Jul. 10, 1998) PO8071 15-Jul-97 Image Creation Method and 6,231,163 Apparatus (IJ04) (Jul. 10, 1998) PO8047 15-Jul-97 Image Creation Method and 6,247,795 Apparatus (IJ05) (Jul. 10, 1998) PO8035 15-Jul-97 Image Creation Method and 6,394,581 Apparatus (IJ06) (Jul. 10, 1998) PO8044 15-Jul-97 Image Creation Method and 6,244,691 Apparatus (IJ07) (Jul. 10, 1998) PO8063 15-Jul-97 Image Creation Method and 6,257,704 Apparatus (IJ08) (Jul. 10, 1998) PO8057 15-Jul-97 Image Creation Method and 6,416,168 Apparatus (IJ09) (Jul. 10, 1998) PO8056 15-Jul-97 Image Creation Method and 6,220,694 Apparatus (IJ10) (Jul. 10, 1998) PO8069 15-Jul-97 Image Creation Method and 6,257,705 Apparatus (IJ11) (Jul. 10, 1998) PO8049 15-Jul-97 Image Creation Method and 6,247,794 Apparatus (IJ12) (Jul. 10, 1998) PO8036 15-Jul-97 Image Creation Method and 6,234,610 Apparatus (IJ13) (Jul. 10, 1998) PO8048 15-Jul-97 Image Creation Method and 6,247,793 Apparatus (IJ14) (Jul. 10, 1998) PO8070 15-Jul-97 Image Creation Method and 6,264,306 Apparatus (IJ15) (Jul. 10, 1998) PO8067 15-Jul-97 Image Creation Method and 6,241,342 Apparatus (IJ16) (Jul. 10, 1998) PO8001 15-Jul-97 Image Creation Method and 6,247,792 Apparatus (IJ17) (Jul. 10, 1998) PO8038 15-Jul-97 Image Creation Method and 6,264,307 Apparatus (IJ18) (Jul. 10, 1998) PO8033 15-Jul-97 Image Creation Method and 6,254,220 Apparatus (IJ19) (Jul. 10, 1998) PO8002 15-Jul-97 Image Creation Method and 6,234,611 Apparatus (IJ20) (Jul. 10, 1998) PO8068 15-Jul-97 Image Creation Method and 6,302,528 Apparatus (IJ21) (Jul. 10, 1998) PO8062 15-Jul-97 Image Creation Method and 6,283,582 Apparatus (IJ22) (Jul. 10, 1998) PO8034 15-Jul-97 Image Creation Method and 6,239,821 Apparatus (IJ23) (Jul. 10, 1998) PO8039 15-Jul-97 Image Creation Method and 6,338,547 Apparatus (IJ24) (Jul. 10, 1998) PO8041 15-Jul-97 Image Creation Method and 6,247,796 Apparatus (IJ25) (Jul. 10, 1998) PO8004 15-Jul-97 Image Creation Method and 09/113,122 Apparatus (IJ26) (Jul. 10, 1998) PO8037 15-Jul-97 Image Creation Method and 6,390,603 Apparatus (IJ27) (Jul. 10, 1998) PO8043 15-Jul-97 Image Creation Method and 6,362,843 Apparatus (IJ28) (Jul. 10, 1998) PO8042 15-Jul-97 Image Creation Method and 6,293,653 Apparatus (IJ29) (Jul. 10, 1998) PO8064 15-Jul-97 Image Creation Method and 6,312,107 Apparatus (IJ30) (Jul. 10, 1998) PO9389 23-Sep-97 Image Creation Method and 6,227,653 Apparatus (IJ31) (Jul. 10, 1998) PO9391 23-Sep-97 Image Creation Method and 6,234,609 Apparatus (IJ32) (Jul. 10, 1998) PP0888 12-Dec-97 Image Creation Method and 6,238,040 Apparatus (IJ33) (Jul. 10, 1998) PP0891 12-Dec-97 Image Creation Method and 6,188,415 Apparatus (IJ34) (Jul. 10, 1998) PP0890 12-Dec-97 Image Creation Method and 6,227,654 Apparatus (IJ35) (Jul. 10, 1998) PP0873 12-Dec-97 Image Creation Method and 6,209,989 Apparatus (IJ36) (Jul. 10, 1998) PP0993 12-Dec-97 Image Creation Method and 6,247,791 Apparatus (IJ37) (Jul. 10, 1998) PP0890 12-Dec-97 Image Creation Method and 6,336,710 Apparatus (IJ38) (Jul. 10, 1998) PP1398 19-Jan-98 Image Creation Method and 6,217,153 Apparatus (IJ39) (Jul. 10, 1998) PP2592 25-Mar-98 Image Creation Method and 6,416,167 Apparatus (IJ40) (Jul. 10, 1998) PP2593 25-Mar-98 Image Creation Method and 6,243,113 Apparatus (IJ41) (Jul. 10, 1998) PP3991 9-Jun-98 Image Creation Method and 6,283,581 Apparatus (IJ42) (Jul. 10, 1998) PP3987 9-Jun-98 Image Creation Method and 6,247,790 Apparatus (IJ43) (Jul. 10, 1998) PP3985 9-Jun-98 Image Creation Method and 6,260,953 Apparatus (IJ44) (Jul. 10, 1998) PP3983 9-Jun-98 Image Creation Method and 6,267,469 Apparatus (IJ45) (Jul. 10, 1998)

[0171] Ink Jet Manufacturing

[0172] Further, the present application may utilize advanced semiconductor fabrication techniques in the construction of large arrays of ink jet printers. Suitable manufacturing techniques are described in the following Australian provisional patent specifications incorporated here by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. Australian US Patent/Patent Provisional Filing Application and Filing Number Date Title Date PO7935 15-Jul- A Method of Manufacture of an Image 6,224,780 97 Creation Apparatus (IJM01) (Jul. 10, 1998) PO7936 15-Jul- A Method of Manufacture of an Image 6,235,212 97 Creation Apparatus (IJM02) (Jul. 10, 1998) PO7937 15-Jul- A Method of Manufacture of an Image 6,280,643 97 Creation Apparatus (IJM03) (Jul. 10, 1998) PO8061 15-Jul- A Method of Manufacture of an Image 6,284,147 97 Creation Apparatus (IJM04) (Jul. 10, 1998) PO8054 15-Jul- A Method of Manufacture of an Image 6,214,244 97 Creation Apparatus (IJM05) (Jul. 10, 1998) PO8065 15-Jul- A Method of Manufacture of an Image 6,071,750 97 Creation Apparatus (IJM06) (Jul. 10, 1998) PO8055 15-Jul- A Method of Manufacture of an Image 6,267,905 97 Creation Apparatus (IJM07) (Jul. 10, 1998) PO8053 15-Jul- A Method of Manufacture of an Image 6,251,298 97 Creation Apparatus (IJM08) (Jul. 10, 1998) PO8078 15-Jul- A Method of Manufacture of an Image 6,258,285 97 Creation Apparatus (IJM09) (Jul. 10, 1998) PO7933 15-Jul- A Method of Manufacture of an Image 6,225,138 97 Creation Apparatus (IJM10) (Jul. 10, 1998) PO7950 15-Jul- A Method of Manufacture of an Image 6,241,904 97 Creation Apparatus (IJM11) (Jul. 10, 1998) PO7949 15-Jul- A Method of Manufacture of an Image 6,299,786 97 Creation Apparatus (IJM12) (Jul. 10, 1998) PO8060 15-Jul- A Method of Manufacture of an Image 09/113,124 97 Creation Apparatus (IJM13) (Jul. 10, 1998) PO8059 15-Jul- A Method of Manufacture of an Image 6,231,773 97 Creation Apparatus (IJM14) (Jul. 10, 1998) PO8073 15-Jul- A Method of Manufacture of an Image 6,190,931 97 Creation Apparatus (IJM15) (Jul. 10, 1998) PO8076 15-Jul- A Method of Manufacture of an Image 6,248,249 97 Creation Apparatus (IJM16) (Jul. 10, 1998) PO8075 15-Jul- A Method of Manufacture of an Image 6,290,862 97 Creation Apparatus (IJM17) (Jul. 10, 1998) PO8079 15-Jul- A Method of Manufacture of an Image 6,241,906 97 Creation Apparatus (IJM18) (Jul. 10, 1998) PO8050 15-Jul- A Method of Manufacture of an Image 09/113,116 97 Creation Apparatus (IJM19) (Jul. 10, 1998) PO8052 15-Jul- A Method of Manufacture of an Image 6,241,905 97 Creation Apparatus (IJM20) (Jul. 10, 1998) PO7948 15-Jul- A Method of Manufacture of an Image 6,451,216 97 Creation Apparatus (IJM21) (Jul. 10, 1998) PO7951 15-Jul- A Method of Manufacture of an Image 6,231,772 97 Creation Apparatus (IJM22) (Jul. 10, 1998) PO8074 15-Jul- A Method of Manufacture of an Image 6,274,056 97 Creation Apparatus (IJM23) (Jul. 10, 1998) PO7941 15-Jul- A Method of Manufacture of an Image 6,290,861 97 Creation Apparatus (IJM24) (Jul. 10, 1998) PO8077 15-Jul- A Method of Manufacture of an Image 6,248,248 97 Creation Apparatus (IJM25) (Jul. 10, 1998) PO8058 15-Jul- A Method of Manufacture of an Image 6,306,671 97 Creation Apparatus (IJM26) (Jul. 10, 1998) PO8051 15-Jul- A Method of Manufacture of an Image 6,331,258 97 Creation Apparatus (IJM27) (Jul. 10, 1998) PO8045 15-Jul- A Method of Manufacture of an Image 6,110,754 97 Creation Apparatus (IJM28) (Jul. 10, 1998) PO7952 15-Jul- A Method of Manufacture of an Image 6,294,101 97 Creation Apparatus (IJM29) (Jul. 10, 1998) PO8046 15-Jul- A Method of Manufacture of an Image 6,416,679 97 Creation Apparatus (IJM30) (Jul. 10, 1998) PO8503 11-Aug- A Method of Manufacture of an Image 6,264,849 97 Creation Apparatus (IJM30a) (Jul. 10, 1998) PO9390 23-Sep- A Method of Manufacture of an Image 6,254,793 97 Creation Apparatus (IJM31) (Jul. 10, 1998) PO9392 23-Sep- A Method of Manufacture of an Image 6,235,211 97 Creation Apparatus (IJM32) (Jul. 10, 1998) PP0889 12-Dec- A Method of Manufacture of an Image 6,235,211 97 Creation Apparatus (IJM35) (Jul. 10, 1998) PP0887 12-Dec- A Method of Manufacture of an Image 6,264,850 97 Creation Apparatus (IJM36) (Jul. 10, 1998) PP0882 12-Dec- A Method of Manufacture of an Image 6,258,284 97 Creation Apparatus (IJM37) (Jul. 10, 1998) PP0874 12-Dec- A Method of Manufacture of an Image 6,258,284 97 Creation Apparatus (IJM38) (Jul. 10, 1998) PP1396 19-Jan- A Method of Manufacture of an Image 6,228,668 98 Creation Apparatus (IJM39) (Jul. 10, 1998) PP2591 25-Mar- A Method of Manufacture of an Image 6,180,427 98 Creation Apparatus (IJM41) (Jul. 10, 1998) PP3989 9-Jun-98 A Method of Manufacture of an Image 6,171,875 Creation Apparatus (IJM40) (Jul. 10, 1998) PP3990 9-Jun-98 A Method of Manufacture of an Image 6,267,904 Creation Apparatus (IJM42) (Jul. 10, 1998) PP3986 9-Jun-98 A Method of Manufacture of an Image 6,245,247 Creation Apparatus (IJM43) (Jul. 10, 1998) PP3984 9-Jun-98 A Method of Manufacture of an Image 6,245,247 Creation Apparatus (IJM44) (Jul. 10, 1998) PP3982 9-Jun-98 A Method of Manufacture of an Image 6,231,148 Creation Apparatus (IJM45) (Jul. 10, 1998)

[0173] Fluid Supply

[0174] Further, the present application may utilize an ink delivery system to the ink jet head. Delivery systems relating to the supply of ink to a series of ink jet nozzles are described in the following Australian provisional patent specifications, the disclosure of which are hereby incorporated by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. US Patent/ Patent Australian Application Provisional Filing and Number Date Title Filing Date PO8003 15-Jul-97 Supply Method and Apparatus 6,350,023 (F1) (Jul. 10, 1998) PO8005 15-Jul-97 Supply Method and Apparatus 6,318,849 (F2) (Jul. 10, 1998) PO9404 23-Sep-97 A Device and Method (F3) 09/113,101 (Jul. 10, 1998)

[0175] MEMS Technology

[0176] Further, the present application may utilize advanced semiconductor microelectromechanical techniques in the construction of large arrays of inkjet printers. Suitable microelectromechanical techniques are described in the following Australian provisional patent specifications incorporated here by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. US Patent/ Australian Patent Provisional Application and Number Filing Date Title Filing Date PO7943 15-Jul-97 A device (MEMS01) PO8006 15-Jul-97 A device (MEMS02) 6,087,638 (Jul. 10, 1998) PO8007 15-Jul-97 A device (MEMS03) 09/113,093 (Jul. 10, 1998) PO8008 15-Jul-97 A device (MEMS04) 6,340,222 (Jul. 10, 1998) PO8010 15-Jul-97 A device (MEMS05) 6,041,600 (Jul. 10, 1998) PO8011 15-Jul-97 A device (MEMS06) 6,299,300 (Jul. 10, 1998) PO7947 15-Jul-97 A device (MEMS07) 6,067,797 (Jul. 10, 1998) PO7945 15-Jul-97 A device (MEMS08) 09/113,081 (Jul. 10, 1998) PO7944 15-Jul-97 A device (MEMS09) 6,286,935 (Jul. 10, 1998) PO7946 15-Jul-97 A device (MEMS10) 6,044,646 (Jul. 10, 1998) PO9393 23-Sep-97 A Device and Method 09/113,065 (MEMS11) (Jul. 10, 1998) PP0875 12-Dec-97 A Device (MEMS12) 09/113,078 (Jul. 10, 1998) PP0894 12-Dec-97 A Device and Method 09/113,075 (MEMS13) (Jul. 10, 1998)

[0177] IR Technologies

[0178] Further, the present application may include the utilization of a disposable camera system such as those described in the following Australian provisional patent specifications incorporated here by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. Australian US Patent/Patent Provisional Application and Filing Number Filing Date Title Date PP0895 12-Dec-97 An Image Creation Method and Apparatus 6,231,148 (IR01) (Jul. 10, 1998) PP0870 12-Dec-97 A Device and Method (IR02) 09/113,106 (Jul. 10, 1998) PP0869 12-Dec-97 A Device and Method (IR04) 6,293,658 (Jul. 10, 1998) PP0887 12-Dec-97 Image Creation Method and 09/113,104 Apparatus (IR05) (Jul. 10, 1998) PP0885 12-Dec-97 An Image Production System 6,238,033 (IR06) (Jul. 10, 1998) PP0884 12-Dec-97 Image Creation Method and 6,312,070 Apparatus (IR10) (Jul. 10, 1998) PP0886 12-Dec-97 Image Creation Method and 6,238,111 Apparatus (IR12) (Jul. 10, 1998) PP0871 12-Dec-97 A Device and Method (IR13) 09/113,086 (Jul. 10, 1998) PP0876 12-Dec-97 An Image Processing Method 09/113,094 and Apparatus (IR14) (Jul. 10, 1998) PP0877 12-Dec-97 A Device and Method (IR16) 6,378,970 (Jul. 10, 1998) PP0878 12-Dec-97 A Device and Method (IR17) 6,196,739 (Jul. 10, 1998) PP0879 12-Dec-97 A Device and Method (IR18) 09/112,774 (Jul. 10, 1998) PP0883 12-Dec-97 A Device and Method (IR19) 6,270,182 (Jul. 10, 1998) PP0880 12-Dec-97 A Device and Method (IR20) 6,152,619 (Jul. 10, 1998) PP0881 12-Dec-97 A Device and Method (IR21) 09/113,092 (Jul. 10, 1998)

[0179] DotCard Technologies

[0180] Further, the present application may include the utilization of a data distribution system such as that described in the following Australian provisional patent specifications incorporated here by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. US Patent/ Patent Australian Application Provisional Filing and Number Date Title Filing Date PP2370 16-Mar-98 Data Processing Method and 09/112,781 Apparatus (Dot01) (Jul. 10, 1998) PP2371 16-Mar-98 Data Processing Method and 09/113,052 Apparatus (Dot02) (Jul. 10, 1998)

[0181] Artcam Technologies

[0182] Further, the present application may include the utilization of camera and data processing techniques such as an Artcam type device as described in the following Australian provisional patent specifications incorporated here by cross-reference. The serial numbers of respective corresponding US patent applications are also provided for the sake of convenience. US Patent/ Patent Australian Application Provisional Filing and Number Date Title Filing Date PO7991 15-Jul-97 Image Processing Method and 09/113,060 Apparatus (ART01) (Jul. 10, 1998) PO7988 15-Jul-97 Image Processing Method and 6,476,863 Apparatus (ART02) (Jul. 10, 1998) PO7993 15-Jul-97 Image Processing Method and 09/113,073 Apparatus (ART03) (Jul. 10, 1998) PO9395 23-Sep-97 Data Processing Method and 6,322,181 Apparatus (ART04) (Jul. 10, 1998) PO8017 15-Jul-97 Image Processing Method and 09/112,747 Apparatus (ART06) (Jul. 10, 1998) PO8014 15-Jul-97 Media Device (ART07) 6,227,648 (Jul. 10, 1998) PO8025 15-Jul-97 Image Processing Method and 09/112,750 Apparatus (ART08) (Jul. 10, 1998) PO8032 15-Jul-97 Image Processing Method and 09/112,746 Apparatus (ART09) (Jul. 10, 1998) PO7999 15-Jul-97 Image Processing Method and 09/112,743 Apparatus (ART10) (Jul. 10, 1998) PO7998 15-Jul-97 Image Processing Method and 09/112,742 Apparatus (ART11) (Jul. 10, 1998) PO8031 15-Jul-97 Image Processing Method and 09/112,741 Apparatus (ART12) (Jul. 10, 1998) PO8030 15-Jul-97 Media Device (ART13) 6,196,541 (Jul. 10, 1998) PO7997 15-Jul-97 Media Device (ART15) 6,195,150 (Jul. 10, 1998) PO7979 15-Jul-97 Media Device (ART16) 6,362,868 (Jul. 10, 1998) PO8015 15-Jul-97 Media Device (ART17) 09/112,738 (Jul. 10, 1998) PO7978 15-Jul-97 Media Device (ART18) 09/113,067 (Jul. 10, 1998) PO7982 15-Jul-97 Data Processing Method and 6,431,669 Apparatus (ART19) (Jul. 10, 1998) PO7989 15-Jul-97 Data Processing Method and 6,362,869 Apparatus (ART20) (Jul. 10, 1998) PO8019 15-Jul-97 Media Processing Method and 6,472,052 Apparatus (ART21) (Jul. 10, 1998) PO7980 15-Jul-97 Image Processing Method and 6,356,715 Apparatus (ART22) (Jul. 10, 1998) PO8018 15-Jul-97 Image Processing Method and 09/112,777 Apparatus (ART24) (Jul. 10, 1998) PO7938 15-Jul-97 Image Processing Method and 09/113,224 Apparatus (ART25) (Jul. 10, 1998) PO8016 15-Jul-97 Image Processing Method and 6,366,693 Apparatus (ART26) (Jul. 10, 1998) PO8024 15-Jul-97 Image Processing Method and 6,329,990 Apparatus (ART27) (Jul. 10, 1998) PO7940 15-Jul-97 Data Processing Method and 09/113,072 Apparatus (ART28) (Jul. 10, 1998) PO7939 15-Jul-97 Data Processing Method and 09/112,785 Apparatus (ART29) (Jul. 10, 1998) PO8501 11-Aug-97 Image Processing Method and 6,137,500 Apparatus (ART30) (Jul. 10, 1998) PO8500 11-Aug-97 Image Processing Method and 09/112,796 Apparatus (ART31) (Jul. 10, 1998) PO7987 15-Jul-97 Data Processing Method and 09/113,071 Apparatus (ART32) (Jul. 10, 1998) PO8022 15-Jul-97 Image Processing Method and 6,398,328 Apparatus (ART33) (Jul. 10, 1998) PO8497 11-Aug-97 Image Processing Method and 09/113,090 Apparatus (ART34) (Jul. 10, 1998) PO8020 15-Jul-97 Data Processing Method and 6,431,704 Apparatus (ART38) (Jul. 10, 1998) PO8023 15-Jul-97 Data Processing Method and 09/113,222 Apparatus (ART39) (Jul. 10, 1998) PO8504 11-Aug-97 Image Processing Method and 09/112,786 Apparatus (ART42) (Jul. 10, 1998) PO8000 15-Jul-97 Data Processing Method and 6,415,054 Apparatus (ART43) (Jul. 10, 1998) PO7977 15-Jul-97 Data Processing Method and 09/112,782 Apparatus (ART44) (Jul. 10, 1998) PO7934 15-Jul-97 Data Processing Method and 09/113,056 Apparatus (ART45) (Jul. 10, 1998) PO7990 15-Jul-97 Data Processing Method and 09/113,059 Apparatus (ART46) (Jul. 10, 1998) PO8499 11-Aug-97 Image Processing Method and 6,486,886 Apparatus (ART47) (Jul. 10, 1998) PO8502 11-Aug-97 Image Processing Method and 6,381,361 Apparatus (ART48) (Jul. 10, 1998) PO7981 15-Jul-97 Data Processing Method and 6,317,192 Apparatus (ART50) (Jul. 10, 1998) PO7986 15-Jul-97 Data Processing Method and 09/113,057 Apparatus (ART51) (Jul. 10, 1998) PO7983 15-Jul-97 Data Processing Method and 09/113,054 Apparatus (ART52) (Jul. 10, 1998) PO8026 15-Jul-97 Image Processing Method and 09/112,752 Apparatus (ART53) (Jul. 10, 1998) PO8027 15-Jul-97 Image Processing Method and 09/112,759 Apparatus (ART54) (Jul. 10, 1998) PO8028 15-Jul-97 Image Processing Method and 09/112,757 Apparatus (ART56) (Jul. 10, 1998) PO9394 23-Sep-97 Image Processing Method and 6,357,135 Apparatus (ART57) (Jul. 10, 1998) PO9396 23-Sep-97 Data Processing Method and 09/113,107 Apparatus (ART58) (Jul. 10, 1998) PO9397 23-Sep-97 Data Processing Method and 6,271,931 Apparatus (ART59) (Jul. 10, 1998) PO9398 23-Sep-97 Data Processing Method and 6,353,772 Apparatus (ART60) (Jul. 10, 1998) PO9399 23-Sep-97 Data Processing Method and 6,106,147 Apparatus (ART61) (Jul. 10, 1998) PO9400 23-Sep-97 Data Processing Method and 09/112,790 Apparatus (ART62) (Jul. 10, 1998) PO9401 23-Sep-97 Data Processing Method and 6,304,291 Apparatus (ART63) (Jul. 10, 1998) PO9402 23-Sep-97 Data Processing Method and 09/112,788 Apparatus (ART64) (Jul. 10, 1998) PO9403 23-Sep-97 Data Processing Method and 6,305,770 Apparatus (ART65) (Jul. 10, 1998) PO9405 23-Sep-97 Data Processing Method and 6,289,262 Apparatus (ART66) (Jul. 10, 1998) PP0959 16-Dec-97 A Data Processing Method 6,315,200 and Apparatus (ART68) (Jul. 10, 1998) PP1397 19-Jan-98 A Media Device (ART69) 6,217,165 (Jul. 10, 1998) 

We claim:
 1. A postcard generator comprising: an image sensor device for capturing an image; an image processor for processing a captured image; and a pagewidth printhead configured to print a captured and processed image on a first side of a print media and to print a postcard format onto a second side of said print media.
 2. A postcard generator according to claim 1 wherein the postcard format includes a token indicating that postage has been paid, said token being printed onto said print media by said printhead.
 3. A postcard generator according to claim 2 wherein said postcard generator is adapted to print a predetermined number of postcards.
 4. A postcard generator according to claim 1 further comprising a print roll including a plurality of tokens pre-marked thereon, the tokens indicating that postage has bee paid.
 5. A postcard generator according to claim 4 wherein the tokens are printed are pre-printed at regularly spaced intervals the surface of the print media adapted to receive the postcard format thereon, the spacing being substantially equal to the size of the printed image to be printed on the other side of the print media.
 6. A postcard generator according to claim 1 wherein the postcard format includes an address zone.
 7. A postcard generator according to claim 1 wherein the postcard format includes a blank zone.
 8. A postcard generator according to claim 1 further including a memory for storing said postcard format.
 9. A postcard generator according to claim 1 further including a print roll adapted to receive an image on one side thereof and a postcard format on an opposite side thereof; and a guillotine adapted to separate a printed postcard from the print roll. 